Controlled Long Chain Branching in EPDM by Post-Reactor Modification

Abstract

The present disclosure provides a process. In an embodiment, the process includes providing a neat ethylene/ propy-lene/non-conjugated polyene terpolymer (n-terpolymer) having a Mooney viscosity (ML (1+4) at 125C) less than 100 Mooney units (MU). The process includes exposing the n-terpolymer to electron beam radiation at a dosage from 0.2 megaRad (MRad) to 1.3 MRad. The process includes forming a branched ethylene/propylene/non-conjugated polyene terpolymer (b-terpolymer) having a Mooney viscosity ML (1+4) at 125C from 25 MU to 135 MU.

Claims

1. A process comprising: providing a neat ethylene/propylene/non-conjugated polyene terpolymer (n-terpolymer) having a Mooney viscosity (ML (1 +4) at 125° C.) less than 100 Mooney units (MU); exposing the n-terpolymer to electron beam radiation at a dosage from 0.2 megaRad (MRad) to 1.3 MRad; and forming 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.

2. The process of claim 1 wherein the n-terpolymer has a rheology ratio from 20 to 65, the process comprising forming a b-terpolymer having a rheology ratio from 55 to 110.

3. The process of claim 1 wherein the n-terpolymer has a phase angle δ greater than or equal to 41°, the process comprising forming a b-terpolymer having a phase angle δ from 20° to 39°.

4. The process of claim 1 comprising forming a b-terpolymer having a mass recovery greater than, or equal to, 85 percent.

5. The process of claim 1 comprising providing an n-terpolymer comprising from 0.5 to 9.0 weight percent norbornene; and forming a b-terpolymer comprising from 0.3 to 8.6 weight percent norbornene.

6. The process of claim 1 comprising providing a neat ethylene/propylene/norbornene terpolymer (n-EPDM) comprising (i) from 50 wt % to 80 wt % percent ethylene, (ii) from 23 to 38 weight percent propylene, and (iii) from 0.5 to 9.0 weight percent norbornene; exposing the n-EPDM to electron beam radiation at a dosage from 0.3 MRad to 0.7 MRad; and forming a branched ethylene/propylene/norbornene terpolymer (b-EPDM) having (A) a Mooney viscosity ML (1 +4) at 125° C. from 35 MU to 120 MU, (B) a rheology ratio from 55 to 110, and (C) a phase angle δ from 25° to 39°.

7. The process of claim 1 comprising providing an n-EPDM wherein the n-EPDM comprises only one type of non-conjugated polyene and the non-conjugated polyene is absent a heteroatom.

8. A composition comprising: a branched ethylene/propylene/non-conjugated polyene terpolymer (b-terpolymer) comprising (A) a Mooney viscosity (ML 1+4 @ 125° C.) from 35 MU to 120 MU; (B) a rheology ratio from 55 to 110; and (C) a phase angle δ from 20° to 39°.

9. The composition of claim 8 wherein the b-terpolymer is neat.

10. The composition of claim 8 wherein the b-terpolymer has a mass recovery greater than, or equal to, 80 percent.

11. The b-terpolymer of claim 8 comprising less than, or equal to, 0.82 parts per million (ppm) vanadium when measured by Inductively Coupled Plasma-Atomic Emission Spectroscopy (ICP-AES).

12. The b-terpolymer of claim 8 comprising (i) from 54 to 72 weight percent ethylene; (ii) from 23 to 55 weight percent propylene; and (iii) from 0.3 to 8.6 weight percent norbornene.

13. The b-terpolymer of claim 8 comprising a density from greater than, or equal to, 0.85 g/cc and less than 0.89 g/cc.

14. The b-terpolymer of claim 8 comprising a chlorine content from greater than, or equal to, 0 parts per million (ppm) to less than, or equal to, 30 parts per million (ppm).

15. The b-terpolymer of claim 8 comprising providing an n-EPDM wherein the n-EPDM comprises only one type of non-conjugated polyene and the non-conjugated polyene is absent a heteroatom.

Description

DETAILED DESCRIPTION

Process

[0040] The present disclosure provides a process. In an embodiment, the process comprises providing an ethylene/propylene/non-conjugated polyene terpolymer. The terpolymer is neat and has a Mooney viscosity less than 100 Mooney units, wherein the Mooney viscosity test condition is ML (1+4) at 125° C. The process includes exposing the neat terpolymer to electron beam radiation. The neat terpolymer is exposed to electron beam radiation at a dosage from 0.2 megaRad (MRad) to 1.3 MRad. The process includes forming a branched ethylene/propylene/non-conjugated polyene terpolymer. The branched terpolymer has a Mooney viscosity from 25 Mooney units to 135 Mooney units.

[0041] The process includes providing a terpolymer. In an a embodiment, the terpolymer is an ethylene/a-olefin/non-conjugated polyene comprising, in polymerized form, ethylene, an α-olefin, and a non-conjugated polyene. Suitable examples of α-olefins include C3-C20 α-olefins or C3-C8 α-olefins. Suitable examples of nonconjugated polyenes include C4-C40 nonconjugated dienes.

[0042] In an embodiment, the α-olefin is a C3-C8 aliphatic α-olefin. In a further embodiment, the α-olefin is selected from the group consisting of propylene, 1-butene, 1-hexene and 1-octene.

[0043] In an embodiment, the α-olefin is propylene.

[0044] In an embodiment, the nonconjugated polyene is an acyclic diene or a cyclic diene. Nonlimiting examples of acyclic dienes include straight chain acyclic dienes, such as 1,4-hexadiene and 1,5-heptadiene; and branched chain acyclic dienes, such as 5-methyl -1,4-hexadiene, 2-methyl-1,5-hexadiene, 6-methyl-1,5-heptadiene, 7-methyl-1,6-octadiene, 3,7-dimethyl-1,6-octadiene, 3,7-dimethyl-1,7-octadiene, 5,7-dimethyl-1,7-octadiene, and 1,9-deca-diene and mixed isomers of dihydromyrcene. Nonlimiting examples of cyclic dienes include monocyclic dienes such as 1,4-cyclohexadiene, 1,5-cyclooctadiene and 1,5-cyclododecadiene; multi-ring alicyclic fused and bridged ring dienes, such as tetrahydroindene and methyl tetrahydroindene; alkenyl, alkylidene, cycloalkenyl and cycloalkylidene norbornenes such as 5-methylene-2-norbornene (MNB), 5-ethylidene-2-norbornene (ENB), 5-vinyl-2-norbornene, 5-propenyl-2-norbornene, 5-isopropylidene-2-norbornene, 5-(4-cyclopentenyl)-2-norbornene, and 5-cyclohexylidene-2-norbornene.

[0045] In an embodiment, the nonconjugated polyene is absent a heteroatom. The term “heteroatom,” as used herein, is an atom other than carbon or hydrogen. The heteroatom can be a non-carbon atom from Groups IV, V, VI and VII of the Periodic Table. Nonlimiting examples of heteroatoms include: F, N, O, P, B, S, and Si.

[0046] In an embodiment, the nonconjugated polyene is ENB.

[0047] In an embodiment, the terpolymer comprises only one type of non-conjugated polyene. The single type of non-conjugated polyene is void, or absent of a heteroatom.

[0048] In an embodiment, the terpolymer is an ethylene/propylene/norbornene terpolymer. In a further embodiment, the terpolymer is an ethylene/propylene/ENB terpolymer. The term “EPDM,” as used herein, is the ethylene/propylene/ENB terpolymer having only three monomers, and the ENB being the sole diene in the terpolymer.

[0049] In an embodiment, the terpolymer is a neat terpolymer. The term “neat,” as used herein, indicates a material that has no oil within, or upon, its structure. The term “neat,” as used herein, interchangeably indicates a material that is “oil-free.” In an embodiment, the EPDM is a neat EPDM, (i.e., “n-EPDM”).

[0050] In an embodiment, n-EPDM used herein is produced with a metallocene catalyst as described in U.S. Pat. No. 8,101,696 the entire contents of which is incorporated by reference herein.

[0051] The n-EPDM has a Mooney viscosity less than 100 MU. In an embodiment, the n-EPDM has a Mooney viscosity from 20 MU, or 30 MU, or 40 MU, or 50 MU, or 60 MU, or 65 MU, or 70 MU to 80 MU, or 85 MU, or 90 MU, or 99 MU. In a further embodiment, the n-EPDM has a Mooney viscosity from 20 to 99 MU, or from 30 to 99 MU, or from 60 to 80 MU.

[0052] In an embodiment, the n-EPDM has a Mooney relaxation area (MLRA), from 25 Mooney unit-seconds (MU.Math.s), or 30 MU.Math.s, or 180 MU.Math.s to 280 MU.Math.s, or 475 MU.Math.s, or 510 MU.Math.s, or 550 MU.Math.s. In a further embodiment, the n-EPDM has a MLRA from 25 to 550 MU.Math.s, or from 30 to 475 MU.Math.s, or from 180 to 280 MU.Math.s.

[0053] In an embodiment, the n-EPDM has an MLRA/ML ratio from 0.5 seconds (s), or 1 s, or 2 s, or 3 s, or 3.3 s to 4 s or 4.5 s or 5 s, or 6 s, or 6.5 s, or 7 s, or 7.5 s or 8 s. In a further embodiment, the n-EPDM has an MLRA/ML ratio from 0.5 to 8 s, or from 2 to 6.6 s, or from 3 to 6 s.

[0054] In an embodiment, the n-EPDM has a rheology ratio (RR) from 20, or 25, or 30 or 35 to 40, or 45, or 50, or 55, or 60, or 65. In a further embodiment, the n-EPDM has an RR from 20 to 65, or from 25 to 60, or from 30 to 55.

[0055] The n-EPDM has a phase angle δ greater than, or equal to, 41°. In an embodiment, the n-EPDM has a phase angle δ from 41°, or 45°, or 50° to 60°, or 70°, or 85°. In a further embodiment, the n-EPDM has a phase angle δ from 41° to 85°, or from 45° to 70°, or from 50° to 60°.

[0056] In an embodiment, the n-EPDM comprises from 50 weight percent (wt %), or 55 wt %, or 60 wt %, or 68 wt % to 70 wt %, or 72 wt %, or 74 wt %, or 80 wt % polymerized ethylene. In a further embodiment, the n-EPDM comprises from 50 to 80 wt %, or from 60 to 74 wt %, or from 68 to 72 wt % polymerized ethylene. In an embodiment, the n-EPDM comprises from 23 wt %, or 25 wt %, to 27 wt %, or 30 wt %, or 35 wt %, or 38 wt % polymerized propylene. In a further embodiment, the n-EPDM comprises from 23 to 38 wt %, or from 25 to 35 wt %, or from 25 to 30 wt % polymerized propylene. In an embodiment, the n-EPDM comprises from 0.5 wt %, or 1 wt %, or 2 wt %, or 3 wt %, or 3.5 wt %, or 4 wt %, or 4.5 wt %, or 4.7 wt % to 5.1 wt %, or 5.5 wt %, or 6 wt %, or 7 wt %, or 8 wt %, or 8.5 wt %, or 9 wt % polymerized ENB. In a further embodiment, the n-EPDM comprises from 0.5 to 9 wt %, or from 0.5 to 8.5 wt %, or from 0.5 to 7 wt %, or from 4 to 5 wt % polymerized ENB. Weight percentages are based upon a total weight of the n-EPDM.

[0057] In an embodiment, the n-EPDM has a molecular weight distribution (MWD) from 1.8, or 2.0, or 2.2, or 2.4, or 2.6 to 3.1, or 3.2, or 3.5, or 4.0, or 5.0. In a further embodiment, the n-EPDM has an MWD from 1.8 to 5.0, or from 2.0 to 4.0, or from 2.2 to 3.5, or from 2.3 to 3.1.

[0058] The n-EPDM may comprise a combination of two or more embodiments as described herein.

[0059] The terpolymer may comprise a combination of two or more embodiments as described herein.

[0060] The process includes exposing the terpolymer (e.g., n-EPDM) to electron beam radiation. In an embodiment, the terpolymer (e.g., n-EPDM) is exposed at a dosage from 0.2 megaRad (MRad), or 0.3 MRad, or 0.4 MRad to 0.5 MRad, or 0.6 MRad, or 0.7 MRad, or 0.8 MRad, or 0.9 MRad, or 1 MRad, or 1.1 MRad, or 1.2 MRad, or 1.3 MRad, or 1.5 MRad. In a further embodiment, the terpolymer (e.g., n-EPDM) is exposed at a dosage from 0.2 to 1.3 MRad, or from 0.3 to 1.2 MRad, or from 0.3 to 0.9 MRad, or from 0.3 to 0.7 MRad, or from 0.4 to 0.5 MRad.

[0061] In an embodiment, the terpolymer (e.g., n-EPDM) is exposed for a dosage time from 1 milliseconds (ms), or 2 ms, or 4 ms, or 6 ms, or 8 ms, or 10 ms to 12 ms, or 14 ms, or 18 ms, or 20 ms, or 30 ms, or 100 ms. In a further embodiment, the terpolymer (e.g., n-EPDM) is exposed for a dosage time from 1 to 100 ms, or from 2 to 30 ms, or from 4 to 20 ms, or from 10 to 20 ms.

[0062] In an embodiment, the process utilizes a linear electron beam accelerator. The terpolymer is exposed to the electron beam radiation in an ambient air environment. The linear electron beam accelerator operates at an energy range of 4.5 MeV, a beam power over the whole energy range of 150 kW, a beam energy spread of +1−10 percent and an average current of 30 milliamps (mA).

[0063] The process includes forming a branched terpolymer (i.e., b-terpolymer). The branched terpolymer is interchangeably referred to as an irradiated terpolymer. The branched terpolymer is a branched ethylene/α-olefin/non-conjugated polyene terpolymer. The a-olefin of the branched ethylene/α-olefin/non-conjugated polyene terpolymer is any α-olefin as described herein. The non-conjugated polyene of the branched ethylene/α-olefin/non-conjugated polyene terpolymer is any non-conjugated polyene as described herein. In an embodiment, the branched terpolymer is a branched ethylene/propylene/ENB terpolymer. The term, “b-EPDM,” as used herein, is the branched ethylene/propylene/ENB terpolymer.

[0064] In an embodiment, the process includes forming a gel-free branched terpolymer. In a further embodiment, the process includes forming a gel-free b-EPDM.

[0065] In an embodiment, the branched terpolymer (e.g., b-EPDM), has a Mooney viscosity from 25 MU, or 35 MU, or 45 MU, or 55 MU, or 75 MU, or 95 MU, or 100 MU, or 105 MU, or 110 MU to 115 MU, or 120 MU, or 122 MU, or 125 MU, or 130 MU, or 135 MU. In a further embodiment, the b-EPDM has a Mooney viscosity from 25 to 135 MU, or from 35 to 120 MU, or from 45 to 110 MU. The irradiated terpolymer (e.g., b-EPDM) has an increased Mooney viscosity compared to the non-irradiated terpolymer.

[0066] In an embodiment, the branched terpolymer (e.g., b-EPDM), has a Mooney relaxation area (MLRA), from 220 MU.Math.s, or 280 MU.Math.s, or 315 MU.Math.s to 940 MU.Math.s, or 1800 MU.Math.s, or 2300 MU.Math.s. In a further embodiment, the b-EPDM has a MLRA from 220 to 2300 MU.Math.s, or from 280 to 1800 MU.Math.s, or from 315 to 940 MU.Math.s. The irradiated terpolymer (e.g., b-EPDM) has an increased MLRA compared to the non-irradiated terpolymer (e.g., n-EPDM).

[0067] In an embodiment, the branched terpolymer (e.g., b-EPDM), has an MLRA/ML ratio from 7 s, or 8 s, or 9 s, or 10 s to 12 s, or 13 s, or 15 s, or 20 s, or 24 s, or 26 s, or 30 s. In a further embodiment, the b-EPDM has a MLRA/ML value from 7 to 30 s, or from 7 to 26 s, or from 10 to 15 s. The irradiated terpolymer (e.g., b-EPDM) has an increased MLRA/ML ratio compared to the non-irradiated terpolymer. Bounded by no particular theory, the MLRA/ML ratio is considered as a relaxation time associated with the degree of melt elasticity of the terpolymer. Long chain branching (LCB), can slow relaxation of the terpolymer and increase the MLRA/ML ratio. The increased MLRA/ML ratio indicates that the irradiated terpolymer contains more LCB compared to the non-irradiated n-EPDM (e.g., n-EPDM).

[0068] In an embodiment, the branched terpolymer (e.g., b-EPDM), has a rheology ratio (RR) from 55, or 60, or 70, or 80, or 90, or 95, or 100 to 105, or 110. In a further embodiment, the b-EPDM has an RR from 55 to 110, or from 60 to 105, or from 70 to 100, or from 80 to 95. The irradiated terpolymer (e.g., b-EPDM) has an increased RR value compared to the non-irradiated terpolymer. Bounded by no particular theory, the increased RR value indicates that the irradiated terpolymer is more highly shear thinning compared to the non-irradiated n-EPDM. The increased RR value indicates that the irradiated terpolymer contains more LCB compared to the non-irradiated n-EPDM.

[0069] In an embodiment, the branched terpolymer (e.g., b-EPDM), has a phase angle δ from 20°, or 22°, or 25°, or 27°, or 29° to 30°, or 31°, or 32°, or 35°, or 37°, or 39°. In a further embodiment, the b-EPDM has a phase angle δ from 20° to 39°, or from 22° to 37°, or from 25° to 35°. Bounded by no particular theory, it is believed that the irradiated terpolymer (e.g., b-EPDM) has a decreased phase angle δ value compared to the non-irradiated n-EPDM. The decreased phase angle δ value indicates that the irradiated terpolymer is more elastic compared to the non-irradiated n-EPDM.

[0070] In an embodiment, the branched terpolymer (e.g., b-EPDM), has a density from greater than, or equal to 0.85 g/cc, or 0.86 g/cc to less than, or equal to, 0.88 g/cc or 0.89 g/cc. In a further embodiment, the b-EPDM has a density from 0.85 to less than 0.89 g/cc, or from 0.86 to 0.88 g/cc.

[0071] In an embodiment, the branched terpolymer (e.g., b-EPDM), comprises vanadium. In an embodiment, the b-EPDM has a vanadium content from greater than, or equal to, 0 parts per million (ppm), or 0.1 ppm to less than, or equal to, 0.7 ppm or 0.82 ppm, or 0.9 ppm. In a further embodiment, the b-EPDM has a vanadium content from 0 to 0.9 ppm or from 0 ppm to less than 0.82 ppm. In an embodiment, the b-EPDM comprises vanadium in an amount less than 0.82 ppm.

[0072] In an embodiment, the branched terpolymer (e.g., b-EPDM), comprises chlorine. In an embodiment, the b-EPDM has a chlorine content from greater than, or equal to, 0 parts per million (ppm), or 10 ppm to 15 ppm, or 30 ppm. In a further embodiment, the b-EPDM has a chlorine content from 0 to 30 ppm or from 0 to 15 ppm.

[0073] In an embodiment, the branched terpolymer (e.g., b-EPDM), comprises from 54 weight percent (wt %), or 55 wt %, or 60 wt % to 65 wt %, or 68 wt % to 72 wt % polymerized ethylene; from 23 wt %, or 25 wt % to 30 wt %, or 40 wt %, or 50 wt %, or 55 wt % polymerized propylene; and from 0.3 wt %, or 0.5 wt %, or 1 wt %, or 2 wt %, or 3 wt %, or 3.5 wt %, or 4 wt %, or 4.5 wt %, or 4.7 wt % to 5.1 wt %, or 5.5 wt %, or 6 wt %, or 7 wt %, or 8 wt %, or 8.6 wt % polymerized ENB. In a further embodiment, the b-EPDM comprises from 54 to 72 wt %, or from 60 to 68 wt % polymerized ethylene; from 23 to 55 wt %, or from 25 to 50 wt % polymerized propylene; and from 0.3 to 8.6 wt %, or from 0.5 to 8 wt % polymerized ENB. Weight percentages are based upon a total weight of the b-EPDM. Bounded by no particular theory, it is believed that the irradiated terpolymer (e.g., b-EPDM) has negligible reduction in ENB content compared to the non-irradiated n-EPDM. The lack of decrease in ENB content indicates an absence of crosslinking in the irradiated terpolymer.

[0074] In an embodiment, the branched terpolymer (e.g., b-EPDM), has an MWD from 2.3, or 2.6, or 3.0, or 3.3 to 4.2, or 5.6, or 6. In a further embodiment, the b-EPDM has an MWD from 2.3 to 6, or from 2.6 to 5.6, or from 3.3 to 4.2.

[0075] In an embodiment, the branched terpolymer (e.g., b-EPDM), has a mass recovery as determined by the HT GPC test. In an embodiment, the b-EPDM has a mass recovery greater than, or equal to, 80%. In a further embodiment, the b-EPDM has a mass recovery from 80%, or 85%,or 90% to 95%, or 96%, or 97%, or 98%, or 99%, or 100%. In another embodiment, the b-EPDM has a mass recovery from 80% to 100%, or from 85% to 100%, or from 97% to 100%.

[0076] In an embodiment, the process includes: [0077] (1) providing a neat ethylene/propylene/norbornene terpolymer comprising (i) from 50 to 80 wt % polymerized ethylene, (ii) from 23 to 38 wt % polymerized propylene, and (iii) from 0.5 to 9 wt % polymerized ENB, wherein weight percentages are based upon a total weight of the terpolymer; [0078] (2) exposing the neat ethylene/propylene/norbornene terpolymer to electron beam radiation at a dosage from 0.3 to 0.7 MRad; and [0079] (3) forming a branched ethylene/propylene/norbornene terpolymer having [0080] (A) a Mooney viscosity from 35 to 120 MU, or from 45 to 110 MU, or from 55 to 105 MU, [0081] (B) a rheology ratio at 125° C. from 55 to 110, or from 60 to 105, or from 70 to 100, and [0082] (C) a phase angle 6 from 28° to 39°, or from 22° to 37°, or from 25° to 35°. [0083] The process may comprise two or more embodiments disclosed herein.

Composition

[0084] The present disclosure provides a composition. In an embodiment, the composition comprises a branched ethylene/propylene/non-conjugated polyene terpolymer. The branched terpolymer has a Mooney viscosity (ML 1+4 @125° C.) from 35 Mooney units (MU) to 120 MU. The branched terpolymer has a rheology ratio from 55 to 110. The branched terpolymer has a phase angle δ from 20° to 39°.

[0085] In an embodiment, the branched terpolymer is the branched ethylene/propylene/ENB terpolymer (i.e., b-EPDM), previously described herein.

[0086] In an embodiment, the b-EPDM is a neat b-EPDM. In a further embodiment, the b-EPDM is a neat and a gel-free b-EPDM.

[0087] In an embodiment, the composition comprises the branched terpolymer (e.g., b-EPDM), in an amount from 5 wt %, or 10 wt %, or 15 wt % to 18 wt %, or 30 wt %, or 50 wt % based a total weight of the composition. In a further embodiment, the composition comprises the branched terpolymer (e.g., b-EPDM), in an amount from 5 to 50 wt %, or from 10 to 30 wt %, or from 15 to 18 wt % based a total weight of the composition.

[0088] In an embodiment, the composition comprises a neat branched terpolymer, (e.g., b-EPDM), having from 68 to 72 wt % polymerized ethylene and from 4.7 to 5 wt % polymerized ENB, the branched terpolymer having one, some, or all of the following properties: [0089] (i) a Mooney viscosity, ML(1 +4) at 125° C., from 36 to 121 MU; and/or [0090] (ii) a rheology ratio V0.1/V100 at 125° C. (RR) from 62 to 102; and/or [0091] (iii) a phase angle δ from 31° to 36°; and/or [0092] (iv) a Mooney relaxation area (MLRA), from 240 to 1795 MU.Math.s; and/or [0093] (v) an MLRA/ML ratio from 7 to 15 s.

[0094] In an embodiment, the composition comprises a neat branched terpolymer, (e.g., b-EPDM), having from 69 to 71 wt % polymerized ethylene and from 0.3 to 0.35 wt % polymerized ENB, the branched terpolymer having one, some or all of the following properties: [0095] (i) a Mooney viscosity, ML(1 +4) at 125° C., from 56 to 63 MU; and/or [0096] (ii) a rheology ratio V0.1/V100 at 125° C. (RR) from 64 to 87; and/or [0097] (iii) a phase angle δ from 31° to 37°; and/or [0098] (iv) a Mooney relaxation area (MLRA), from 348 to 630 MU.Math.s; and/or [0099] (v) an MLRA/ML ratio from 7 to 10 s.

[0100] In an embodiment, the composition comprises a neat branched terpolymer, (e.g., b-EPDM), having from 54 to 55 wt % polymerized ethylene and from 8 to 9 wt % polymerized ENB, the branched terpolymer having one, some or all of the following properties: [0101] (i) a Mooney viscosity, ML(1 +4) at 125° C., from 37 to 103 MU; and/or [0102] (ii) a rheology ratio V0.1/V100 at 125° C. (RR) from 57 to 107; and/or [0103] (iii) a phase angle δ from 32° to 38°; and/or [0104] (iv) a Mooney relaxation area (MLRA), from 315 to 2005 MU.Math.s; and/or [0105] (v) an MLRA/ML ratio from 8 to 20 s.

[0106] In an embodiment, the composition has a vanadium content from greater than, or equal to, 0 parts per million (ppm), or 0.1 ppm to less than, or equal to, 0.7 ppm or 0.82 ppm, or 0.9 ppm. In a further embodiment, the b-EPDM has a vanadium content from 0 to 0.9 ppm or from 0 ppm to less than 0.82 ppm. In an embodiment, the composition comprises vanadium in an amount less than 0.82 ppm.

[0107] In an embodiment, the composition has a chlorine content from greater than, or equal to, 0 parts per million (ppm), or 10 ppm to 15 ppm, or 30 ppm. In a further embodiment, the b-EPDM has a chlorine content from 0 to 30 ppm or from 0 to 15 ppm.

Additives

[0108] The present composition may optionally contain one or more additives.

[0109] In an embodiment, the composition includes the b-EPDM and an oil. The b-EPDM can be any b-EPDM previously disclosed herein. Oils include, but are not limited to, petroleum oils, such as aromatic and naphthenic oils; polyalkylbenzene oils; organic acid monoesters, such as alkyl and alkoxyalkyl oleates and stearates; organic acid diesters, such as dialkyl, dialkoxyalkyl, and alkyl aryl phthalates, terephthalates, sebacates, adipates, and glutarates; glycol diesters, such as tri-, tetra-, and polyethylene glycol dialkanoates; trialkyl trimellitates; trialkyl, trialkoxyalkyl, alkyl diaryl, and triaryl phosphates; chlorinated paraffin oils; coumarone-indene resins; pine tars; vegetable oils, such as castor, tall, rapeseed, and soybean oils and esters and epoxidized derivatives thereof; and combinations thereof. In a further embodiment, the oil is selected from the group consisting of SUNPAR 2280, PARALUX 6001, HYDROBRITE 550, and CALSOL 5550.

[0110] In an embodiment, the composition comprises the oil in an amount from 5 wt %, or 15 wt %, or 20 wt % to 30 wt %, or 40 wt %, or 70 wt % based a total weight of the composition. In a further embodiment, the composition comprises the oil in an amount from 5 to 70 wt %, or from 15 to 40 wt %, or from 20 to 30 wt % based a total weight of the composition.

[0111] The oil may comprise a combination of two or more embodiments as described herein.

[0112] In an embodiment, the composition includes the b-EPDM and an additive. The b-EPDM can be any b-EPDM previously disclosed herein. Suitable additives include, but are not limited to, fillers, antioxidants and antiozonants, UV stabilizers, flame retardants, colorants or pigments, curing agents (e.g., sulphur, peroxides), accelerators, coagents, processing aids, blowing agents, plasticizers and combinations thereof.

[0113] Fillers include, but are not limited to, carbon black; silicates of aluminum, magnesium, calcium, sodium, potassium and mixtures thereof; carbonates of calcium, magnesium and mixtures thereof; oxides of silicon, calcium, zinc, iron, titanium, and aluminum; sulfates of calcium, barium, and lead; polyethylene glycol (PEG); sulfur; stearic acid; sulfonamide; alumina trihydrate; magnesium hydroxide; precipitated silica; fumed silica; natural fibers; synthetic fibers; and combinations thereof.

[0114] Antioxidants and antiozonants include, but are not limited to, hindered phenols, bisphenols, and thiobisphenols; and substituted hydroquinones.

[0115] In an embodiment, the composition includes the b-EPDM and calcium carbonate. In an embodiment, the calcium carbonate is present in an amount from 5 wt %, or 15 wt %, or 20 wt % to 30 wt %, or 40 wt %, or 70 wt % based a total weight of the composition. In a further embodiment, the calcium carbonate is present in an amount from 5 to 70 wt %, or from 15 to 40 wt %, or from 20 to 30 wt % based a total weight of the composition.

[0116] In an embodiment, the composition includes the b-EPDM and carbon black. In an embodiment, the carbon black is present in an amount from 5 wt %, or 15 wt %, or 20 wt % to 30 wt %, or 40 wt %, or 70 wt % based a total weight of the composition. In a further embodiment, the carbon black is present in an amount from 5 to 70 wt %, or from 15 to 40 wt %, or from 20 to 30 wt % based a total weight of the composition.

[0117] In an embodiment, the composition comprises an aggregate additive load, the load excluding calcium carbonate and carbon black. In an embodiment, the aggregate additive load is present in an amount from 0.5 wt %, or 1 wt %, or 2 wt % to 4 wt %, or 5 wt %, or 10 wt % based a total weight of the composition. In a further embodiment, the aggregate additive load is present in an amount from 0.5 to 10 wt %, or from 1 to 5 wt %, or from 2 to 4 wt % based a total weight of the composition.

[0118] The additive may comprise two or more embodiments disclosed herein.

[0119] The aggregate additive load may comprise two or more embodiments disclosed herein.

[0120] In an embodiment, the composition comprises the branched terpolymer (e.g., b-EPDM), in an amount from 5 wt %, or 10 wt %, or 15 wt % to 18 wt %, or 30 wt %, or 50 wt % based a total weight of the composition. In a further embodiment, the composition comprises the branched terpolymer (e.g., b-EPDM), in an amount from 5 to 50 wt %, or from 10 to 30 wt %, or from 15 to 18 wt % based a total weight of the composition.

[0121] The composition may comprise two or more embodiments disclosed herein.

[0122] The composition can be used to form an article. Nonlimiting examples of articles that can be formed with the composition include belts, cable, extruder profiles, hose, molded goods, roofing membranes, sponges, tires, weather stripping, and wire.

[0123] The present disclosure is described more fully through the following examples. Unless otherwise noted, all parts and percentages are by weight.

EXAMPLES

[0124] The raw materials used to formulate the Comparative Samples (“CS”) and the Inventive Examples (“IE”) are provided in Table 1 below.

TABLE-US-00001 TABLE 1 Trade Name Description Supplier NORDEL 4725 70 wt % C.sub.2H.sub.4; The Dow Chemical 5.0 wt % ENB; 25 MU Company NORDEL 4760 67.5 wt % C.sub.2H.sub.4; The Dow Chemical 5.0 wt % ENB; 60 MU Company NORDEL 4770 70 wt % C.sub.2H.sub.4; The Dow Chemical 5.0 wt % ENB; 70 MU Company NORDEL 3745 70 wt % C.sub.2H.sub.4; The Dow Chemical 0.5 wt % ENB; 45 MU Company NORDEL 4785 68 wt % C.sub.2H.sub.4; The Dow Chemical 4.9 wt % ENB; 85 MU Company NORDEL 6530 55 wt % C.sub.2H.sub.4; The Dow Chemical 8.5 wt % ENB; 30 Company NORDEL 6565 55 wt % C.sub.2H.sub.4; The Dow Chemical 8.5 wt % ENB; 65 MU Company Royalene 539 70.6 wt % C.sub.2H.sub.4; Lion Copolymer LLC 4.6 wt % ENB; 70 MU Royalene 539HM 70.6 wt % C.sub.2H.sub.4; Lion Copolymer LLC 4.6 wt % ENB; 80 MU

[0125] Comparative Samples CS1, CS4, CS9, CS12, CS15, CS18 and CS19 are non-irradiated base neat EPDMs used as received. Comparative Samples CS7 and CS8 are Z-N catalyzed neat EPDMs used as received. See Table 2.

[0126] Branched EPDMs (b-EPDMs) are produced by irradiating the neat EPDMs for a dosage time from 10 to 20 milliseconds (ms) using a DYNAMITRON linear electron beam accelerator in air (Table 2) The operating parameters of the electron-beam accelerator are: an energy range of 4.5 MeV, a beam power over the whole energy range of 150 kW, a beam energy spread of +1−10 percent and an average current of 30 milliamps (mA).

[0127] Comparative Samples CS2 and CS3 are produced by irradiating CS1. Comparative Samples CS6, CS11, CS14, and CS17 are produced by irradiating CS4, CS9, CS12 and CS15, respectively.

[0128] Inventive Examples IE1 and IE2 are produced by irradiating CS1. Inventive Examples IE3 and IE4 are produced by irradiating CS4. Inventive Examples IE5 and IE6 are produced by irradiating CS9 and CS12, respectively. Inventive Examples IE7 and IE8 are produced by irradiating CS15. Inventive Examples IE9 and IE10 are produced by irradiating CS18. Inventive Examples IE11 and IE12 are produced by irradiating CS19.

[0129] Table 2 summarizes the results of irradiation upon a range of properties for the Comparative Samples and the Inventive Examples. Table 2 includes vanadium content (V) and chlorine content (CI) from the residual elemental analysis test. The abbreviation N.M. indicates that a property was not measured for the indexed sample.

TABLE-US-00002 TABLE 2 MLRA, MLRA/ den- M- Dosage MV (MU .Math. ML δ sity V Cl REC C2 C3 ENB ID Description (MRad) (MU) s) (s) RR (°) MWD (g/cc) (ppm) (ppm) (%) (wt %) (wt %) (wt %) CS1 NORDEL 4725 0 24.8 36 1.5 26.1 46 3.11 0.88 N.M. N.M. 100 71.43 23.54 5.03 CS2 NORDEL 4725: 0.3 0.3 28.7 90 3.1 42.3 41 3.39 0.88 N.M. N.M. 100 71.91 23.28 4.82 IE1 NORDEL 4725: 0.7 0.7 36.9 242 6.6 62.2 36 4.19 0.88 N.M. N.M. 100 71.55 23.51 4.94 IE2 NORDEL 4725: 1.1 1.1 48.3 635 13.1 93.8 32 5.56 0.88 N.M. N.M. N.M. 71.44 23.82 4.74 CS3 NORDEL 4725: 1.5 1.5 79.9 1818 22.8 123.9 26 N.M. 0.88 N.M. N.M. <85 N.M. N.M. N.M. CS4 NORDEL 4760 0 59.5 210 3.5 45.0 46 2.71 0.88 <0.82 7.6 100 68.14 27.1  4.76 CS5 NORDEL 4760: 0.3 0.3 66.9 423 6.3 60.4 40 3.05 0.88 <0.82 <5 99 68.14 27.2  4.66 IE3 NORDEL 4760: 0.5 0.5 78.5 828 10.5 79.2 35 3.61 0.88 N.M. N.M. 97 N.M. N.M. N.M. IE4 NORDEL 4760: 0.7 0.7 81.1 937 11.5 84.2 34 3.77 0.88 <0.82 <5 98 68.04 27.19 4.77 CS6 NORDEL 4760: 1.5 1.5 163.1 5190 31.8 155.3 22 N.M. 0.88 N.M. N.M. <85 N.M. N.M. N.M. CS7 Royalene 539 0 68.3 332 4.9 50.8 45 N.M. 0.88  4.59 57.1 N.M. N.M. N.M. N.M. CS8 Royalene 539HM 0 86.5 510 5.9 59.0 46 N.M. 0.88 5.6 65.8 N.M. N.M. N.M. N.M. CS9 NORDEL 4770 0 69.4 184 2.7 42.5 48 2.61 0.88 N.M. N.M. 100 N.M. N.M. N.M. CS10 NORDEL 4770: 0.3 0.3 79.2 473 6.0 61.0 41 3.01 0.88 N.M. N.M. 99 71.25 23.87 4.88 IE5 NORDEL 4770: 0.7 0.7 107.4 1575 14.7 102.2 31 4.28 0.88 N.M. N.M. 96 71.18 24.07 4.75 CS11 NORDEL 4770: 1.5 1.5 162.2 8308 51.2 N.M. N.M. N.M. 0.88 N.M. N.M. <85 N.M. N.M. N.M. CS12 NORDEL 4785 0 83.8 276 3.3 43.7 50 2.37 0.88 <0.82 6.5 100 N.M. N.M. N.M. CS13 NORDEL 4785: 0.3 0.3 94.2 535 5.7 62.6 44 2.57 0.88 <0.82 8.3 97 69.14 25.81 5.05 IE6 NORDEL 4785: 0.7 0.7 120.4 1793 14.9 99.8 33 3.53 0.88 <0.82 <5 100 68.97 26.15 4.88 CS14 NORDEL 4785: 1.5 1.5 165.1 9269 56.1 N.M. N.M. N.M. 0.88 N.M. N.M. <85 N.M. N.M. N.M. CS15 NORDEL 3745 0 41.1 143 3.5 38.5 45 2.39 0.88 N.M. N.M. 100 69.83 29.67 0.5  CS16 NORDEL 3745: 0.3 0.3 48.7 221 4.5 49.3 41 2.45 0.88 N.M. N.M. 100 69.94 29.74 0.31 IE7 NORDEL 3745: 0.7 0.7 53.6 349 6.5 64.0 37 2.90 0.88 N.M. N.M. 100 70.07 29.61 0.32 IE8 NORDEL 3745: 1.1 1.1 62.8 629 10.0 86.9 31 3.42 0.88 N.M. N.M. N.M. 69.98 29.7  0.31 CS17 NORDEL 3745: 1.5 1.5 78.4 1292 16.5 126.2 25 N.M. 0.88 N.M. N.M. <85 N.M. N.M. N.M. CS18 NORDEL 6530 0 32.0 206 6.4 43.0 41 3.15 0.86 <0.82 8.5 92 54.67 36.92 8.41 IE9 NORDEL 6530- 0.3 0.3 37.0 316 8.5 57.5 39 3.39 0.86 <0.82 <5 88 54.62 36.91 8.47 IE10 NORDEL 6530- 0.7 0.7 47.0 661 14.1 79.1 35 4.21 0.86 <0.82 <5 88 54.66 37.27 8.06 CS19 NORDEL 6565 0 66.0 472 67.2 63.5 41 2.86 0.86 <0.82 <5 88 54.69 36.49 8.81 IE11 NORDEL 6565- 0.3 0.3 74.0 681 9.1 81.6 37 3.12 0.86 <0.82 <5 90 54.67 36.79 8.55 IE12 NORDEL 6565- 0.7 0.7 103.0 2002 19.3 106.4 32 4.30 0.86 <0.82 11.6 88 54.65 54.65 8.57

[0130] Table 2 shows that the b-EPDMs have increased MV values compared to the base EPDMs. For NORDEL 4760, NORDEL 4770, NORDEL 4785, and NORDEL 6565, MV increased from 59.5 MU to 81.1 MU (IE4), from 69.4 MU to 107.4 MU (IE5), from 83.8 MU to 120.4 MU (IE6), and from 66 MU to 103 MU (IE12, respectively, after being irradiated at a dosage of 0.7 MRad. The MV values of CS6 (163.1), CS11 (162.2 MU), and CS14 (165.1 MU) were accompanied by evidence of macro-gel formation that indicates that the b-EPDM has undesired crosslinking after being irradiated at a dosage of 1.5 MRad.

[0131] Applicant unexpectedly discovered that irradiating NORDEL 4770 at a dosage of 0.7 MRad (IE5), transformed the MV from 69.4 MU to 107.4, the RR from 42.5 to 102.2, and the phase angle δ from 48 to 31. Irradiating NORDEL 4785 at a dosage of 0.7 MRad (IE6), transformed the MV from 83.8 MU to 120.4, the RR from 43.7 to 99.8, and the δ from 50 to 33.

[0132] Table 2 summarizes the results of electron bean radiation upon values for molecular weight distribution (MWD) and mass recovery (M-REC). Applicant unexpectedly discovered that irradiating NORDEL 4725 (IE1), NORDEL 4785 (IE6), and NORDEL 3745 (IE7) at a dosage of 0.7 MRad produced a b-EPDM having a mass recovery of 100 percent. A mass recovery of 100 percent demonstrates chain branching is present in the absence of crosslinking in the b-EPDMs.

[0133] It is specifically intended that the present disclosure not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come with the scope of the following claims.