Abstract: Provided herein are thermoplastic vulcanizates that comprise rubber, broad molecular weight distribution polypropylene, and oil, where the rubber forms a rubber phase that is dispersed and at least partially cross-linked within a continuous thermoplastic component that comprises the broad molecular weight distribution polypropylene. The broad molecular weight distribution polypropylene preferably has a molecular weight distribution (Mw/Mn) of greater than 4; a melt flow rate of greater than 1 g/10 min; and a weight average molecular weight (Mw) of greater than 380,000 daltons.

Abstract: Described herein are thermoplastic vulcanizates comprising propylene-based elastomers and methods for producing the same. The thermoplastic vulcanizates comprise rubber, at least 10 wt % of thermoplastic resin, from 1 to 9 wt % of propylene-based elastomer, oil, and at least 5 wt % of one or more fillers. The thermoplastic vulcanizates are made by a method where the propylene-based elastomer is introduced to the extrusion reactor before the curative is introduced to the extrusion reactor.

Abstract: The invention is directed to a method of forming an annular component useful as an air barrier comprising wrapping a sheet around a building drum to create an annular component having overlapping opposing edges thereby forming an overlapping seam, the sheet having a modulus as determined according to ASTM D412-92 greater than about 6.5 MPa, wherein the edges of the seam are modified prior to wrapping.

Abstract: A coextrusion process for coextruding a thermoplastic elastomer with two outer layers of adhesive to form a film, and a laminate comprising a plurality of layers including an adhesive layer, a sublayer and a barrier layer. The barrier layer comprises a dynamically vulcanized thermoplastic elastomer composition present in one or more plies of the barrier layer. The sublayer comprises a first ply of a first adhesive composition joining the barrier layer and a second ply, and the adhesive layer comprises the second ply, which is vulcanizable with diene-based rubber. The sublayer of the adhesive can be laid down in contact with the relatively hot thermoplastic elastomer to moderate the temperature of the outer layer of the adhesive, whereby the outer layer of the adhesive at least is protected from scorching and can be co-vulcanized with rubber in a tire building process.

Abstract: Disclosed herein is a process to produce a laminate comprises coating at least an outer surface of a dynamically vulcanized alloy film with an adhesive composition to produce the laminate, wherein the adhesive layer has a thickness of less than or equal to about 5 microns, wherein the dynamically vulcanized alloy film comprises a thermoplastic elastomer composition containing a thermoplastic resin as a continuous phase, and a rubber composition dispersed therein, as a dispersed phase. A laminate and a pneumatic tire comprising the laminate are also disclosed.

Abstract: Disclosed herein is a process to form a dynamically vulcanized thermoplastic elastomer film, also referred to as the DVA film, directly from a DVA raw material. The process comprises the steps of: 1) forming a thermoplastic elastomeric material melt comprising an elastomer and a thermoplastic resin in a first mixer under conditions such that the thermoplastic elastomeric material is dynamically vulcanized; 2) passing the thermoplastic elastomeric material melt formed in the first mixer through a second mixer to form a uniformed melt; and 3) passing the thermoplastic elastomeric material melt exiting from the second mixer through a film die to form a thermoplastic elastomer material film.

Abstract: A process to produce a laminate comprising coextruding a dynamically vulcanized alloy (DVA) film with an adhesive layer comprising a vulcanizable elastomeric composition through a die to produce the laminate. The process provides a residence time of the vulcanizable elastomeric composition in the melt to partially scorch the vulcanizable elastomeric composition. A melt of the DVA is in contact with the melt of the vulcanizable elastomeric composition in the die for at least 5 seconds, optionally also with a change in the area of the contact between the DVA film and the adhesive layer as it passes through the die, to increase the adhesion between the adhesive layer and the DVA layer relative to a shorter co-residence time. A laminate and a pneumatic tire comprising the laminate are also disclosed.

Abstract: A layered structure suitable for use in a pneumatic tire as an innerliner is prepared by directly bonding a fluid permeation prevention film and an adhesive tie layer. Prior to the bonding, the fluid permeation prevention layer is treated to remove any residual plasticizers or oils on the surface of the film. The tie layer comprises 100 weight % of at least one halogenated isobutylene containing elastomer and about 1 to about 20 parts per hundred (phr) of at least one tackifier. The fluid permeation prevention film comprises an elastomeric component dispersed in a vulcanized or partially vulcanized state, as a discontinuous phase, in a matrix of the thermoplastic resin component. The two layers of the layered structure may be separately extruded and then adhered to each other or adhered to each other during a calendaring operation wherein the adhesive tie layer composition is coated onto the treated film.

Abstract: This disclosure is directed to a tire innerliner comprising a dynamically vulcanized alloy of an elastomer and an engineering resin; wherein the innerliner is contoured. The disclosure further relates to methods of making such innerliners and tires made from such innerliners.

Abstract: Disclosed herein is a process to produce a laminate comprises coating at least an outer surface of a dynamically vulcanized alloy film with an adhesive composition to produce the laminate, wherein the adhesive layer has a thickness of less than or equal to about 5 microns, wherein the dynamically vulcanized alloy film comprises a thermoplastic elastomer composition containing a thermoplastic resin as a continuous phase, and a rubber composition dispersed therein, as a dispersed phase. A laminate and a pneumatic tire comprising the laminate are also disclosed.

Abstract: A process to produce a laminate comprising coextruding a dynamically vulcanized alloy (DVA) film with an adhesive layer comprising a vulcanizable elastomeric composition through a die to produce the laminate. The process provides a residence time of the vulcanizable elastomeric composition in the melt to partially scorch the vulcanizable elastomeric composition. A melt of the DVA is in contact with the melt of the vulcanizable elastomeric composition in the die for at least 5 seconds, optionally also with a change in the area of the contact between the DVA film and the adhesive layer as it passes through the die, to increase the adhesion between the adhesive layer and the DVA layer relative to a shorter co-residence time. A laminate and a pneumatic tire comprising the laminate are also disclosed.

Abstract: A layered structure suitable for use in a pneumatic tire as an innerliner is prepared by directly bonding a fluid permeation prevention film and an adhesive tie layer. Prior to the bonding, the fluid permeation prevention layer is treated to remove any residual plasticizers or oils on the surface of the film. The tie layer comprises 100 weight % of at least one halogenated isobutylene containing elastomer and about 1 to about 20 parts per hundred (phr) of at least one tackifier. The fluid permeation prevention film comprises an elastomeric component dispersed in a vulcanized or partially vulcanized state, as a discontinuous phase, in a matrix of the thermoplastic resin component. The two layers of the layered structure may be separately extruded and then adhered to each other or adhered to each other during a calendaring operation wherein the adhesive tie layer composition is coated onto the treated film.

Abstract: A coextrusion process for coextruding a thermoplastic elastomer with two outer layers of adhesive to form a film, and a laminate comprising a plurality of layers including an adhesive layer, a sublayer and a barrier layer. The barrier layer comprises a dynamically vulcanized thermoplastic elastomer composition present in one or more plies of the barrier layer. The sublayer comprises a first ply of a first adhesive composition joining the barrier layer and a second ply, and the adhesive layer comprises the second ply, which is vulcanizable with diene-based rubber. The sublayer of the adhesive can be laid down in contact with the relatively hot thermoplastic elastomer to moderate the temperature of the outer layer of the adhesive, whereby the outer layer of the adhesive at least is protected from scorching and can be co-vulcanized with rubber in a tire building process.

Abstract: Articles such as, for example, pipes or bottles, prepared from multimodal polyethylenes possessing a density from 0.940 to 0.965 g/cm3, and an I21 from 4 to 20 dg/min, and comprising a low molecular weight ethylene copolymer having a weight average molecular weight from 5,000 amu to 50,000 amu; and a high molecular weight ethylene copolymer having a weight average molecular weight from 60,000 amu to 800,000 amu, both components having a desirable balance of short chain branching making the multimodal polyethylene suitable for films, pipes, rotomolding applications and blow molding applications.

Abstract: A process is provided for extruding a bimodal polyethylene resin. The process includes providing a polyethylene homopolymer or copolymer resin having a bimodal molecular weight distribution; conveying the resin through an extruder having a feed zone in which the resin is not melted, a melt-mixing zone in which at least a portion of the resin is melted, and a melt zone in which the resin is in a molten state, each zone being partially filled with the resin; and contacting the molten resin in the melt zone with a gas mixture of 8 to 40% by volume O2. The resin can be further pelletized. The oxygen-tailored resin can be used to make polyethylene films having improved bubble stability.

Abstract: Methods of controlling the flow index and/or molecular weight split of a polymer composition are disclosed. The method of producing a polymer composition in one embodiment comprises incorporating a high molecular weight polymer into a low molecular weight polymer to form the polymer composition in a single polymerization reactor in the presence of polymerizable monomers, a bimetallic catalyst composition and at least one control agent; wherein the control agent is added in an amount sufficient to control the level of incorporation of the high molecular weight polymer, the level of low molecular weight polymer, or both. Examples of control agents include alcohols, ethers, amines and oxygen.

Abstract: A film comprising a polyethylene composition, the polyethylene composition in one embodiment comprising a high molecular weight component having a weight average molecular weight of greater than 50,000 amu and a low molecular weight component having a weight average molecular weight of less than 50,000 amu; the polyethylene composition possessing a density of between 0.940 and 0.970 g/cm3, and an I21 value of less than 20 dg/min; characterized in that the polyethylene composition extrudes at an advantageously high specific throughput at an advantageously low melt temperature, and wherein the film has a gel count of less than 100.

Abstract: A film comprising a polyethylene composition, the polyethylene composition in one embodiment comprising a high molecular weight component having a weight average molecular weight of greater than 50,000 amu and a low molecular weight component having a weight average molecular weight of less than 50,000 amu; the polyethylene composition possessing a density of between 0.940 and 0.970 g/cm3, and an I21 value of less than 20 dg/min; characterized in that the polyethylene composition extrudes at an advantageously high specific throughput at an advantageously low melt temperature, and wherein the film has a gel count of less than 100.

Abstract: Films and methods of forming films comprising first combining in a reactor olefins, a catalyst composition and an activator; wherein the activator is present from less than 50 wt % in a diluent by weight of the activator and diluent; followed by isolating a polyolefin having a density of from 0.940 to 0.980 g/cm3; and finally, extruding the polyolefin into a film having a gel count of less than 200 gels/m2.

Abstract: A film comprising a polyethylene composition, the polyethylene composition in one embodiment comprising a high molecular weight component having a weight average molecular weight of greater than 50,000 amu and a low molecular weight component having a weight average molecular weight of less than 50,000 amu; the polyethylene composition possessing a density of between 0.940 and 0.970 g/cm3, and an I21 value of less than 20 dg/min; characterized in that the polyethylene composition extrudes at an advantageously high specific throughput at an advantageously low melt temperature, and wherein the film has a gel count of less than 100.