Abstract: This invention relates to a process for the manufacture of a blend composition of a neutralized sulfonated ethylene propylene terpolymer (EPDM) which includes the steps of sulfonating the EPDM dissolved in a solvent to form an unneutralized sulfonated elastomeric polymer. The solution of the unneutralized sulfonated EPDM is quenched with an aliphatic alcohol. The unneutralized sulfonated elastomeric polymer in solution is then neutralized with a neutralizing agent to form the neutralized sulfonated EPDM in solution. A critically selected non-polar backbone process oil is added under agitation to the solution thereby plasticizing the neutralized sulfonated EPDM with the process oil. The neutralized sulfonated EPDM plasticized with the process oil is then recovered from the solution.

Abstract: This invention relates to a process for the formation of a neutralized sulfonated polymer having about 10 to about 60 meq. sulfonate groups, wherein the sulfonate groups are neutralized with a zinc counterion. A cement of a polymer having olefinic functional groups and a non-reactive solvent is contacted with a sulfonated agent such as an acyl sulfate. The sulfonated polymer is then neutralized with a solution of zinc acetate dissolved in a solvent system of methanol alone or methanol and water, wherein the volume percent of methanol based on non-reactive solvent is less than about 10. A carboxylic acid can be then added to the cement of the neutralized sulfonated polymer thereby forming a zinc salt of the carboxylic acid in situ, wherein the zinc salt of the carboxylic acid is a preferential plasticizer for the zinc sulfonate groups. The Brookfield viscosity at 0.6 rpm at room temperature of the cement of the zinc neutralized sulfonated polymer is less than about 50,000 cps.

Abstract: This invention relates to an improved process for the formation of an improved gel-free neutralized sulfonated elastomeric polymer having about 10 to about 50 meq. unneutralized sulfonate groups, wherein the unneutralized sulfonate groups are neutralized with a metal counterion being selected from the group including lithium, sodium, potassium, cesium, barium, calcium, magnesium, zinc, lead, iron (II), copper (II), mercury (II), and nickel. A cement of an elastomeric polymer having olefinic functional groups dissolved in a non-reactive solvent is contacted with a sulfonating agent such as an acyl sulfate thereby sulfonating the elastomeric polymer, and the sulfonation reaction is subsequently quenched by the addition of isopropanol at a concentration level of about 5 to about 30 volume percent based on a volume of the non-reactive solvent.

Abstract: The instant invention relates to unique and novel ionic polymer compositions which are characterized as being processable at high temperatures, for example, 200.degree. C., while retaining adequate physical properties at both room temperature and elevated temperatures which are below the processing temperature. The ionic polymer compositions include a metal neutralized sulfonated polymer which is plasticized with a preferential plasticizer, at a concentration level of about at least 7 parts by weight per 100 parts of the metal neutralized sulfonated polymer. The preferential plasticizer acts to disrupt the ionic association of the metal or ammonium salt groups of the neutralized sulfonated polymer, thus allowing the ionic polymer to act as a noncrosslinked material at the processing temperature. When the composition is in this state, it can be compounded with oils, fillers, etc. The plasticized metal neutralized sulfonated polymer has excellent physical properties at room temperature and up to 100.degree. C.

Abstract: This invention relates to elastomeric blend compositions of a neutralized sulfonated elastomeric polymer. The compositions include a major portion of a sulfonated elastomeric polymer and a minor proportion of a non-polar wax, wherein the resultant composition has both improved physical and rheological properties.

Abstract: An improved process for the sulfonation of an unsaturated elastomeric polymer to form a sulfonated elastomeric polymer, wherein a cement which contains an elastomeric polymer dissolved in a non-reactive solvent is contacted with a sulfonating agent at between about -100.degree. C. and +100.degree. C. for a period of time sufficient to result in the sulfonation of the elastomeric polymer wherein the improvement includes the use of a sulfonating agent which is formed from mixtures of a sulfur trioxide donor complexed with a Lewis base and a carboxylic acid anhydride ##STR1## or an acyl halide ##STR2## or with both, wherein R is selected from the group consisting of CH.sub.3 --, C.sub.2 H.sub.5 --, C.sub.3 H.sub.7 --, C.sub.4 H.sub.9 --, C.sub.5 H.sub.11, C.sub.6 H.sub.13 and C.sub.6 H.sub.5 and mixtures thereof. The molar ratio of ##STR3## and/or ##STR4## with the SO.sub.3 of the complex is at least 0.5.

Abstract: An improved process for the sulfonation of an unsaturated elastomeric polymer to form a sulfonated elastomeric polymer, wherein a cement which contains an elastomeric polymer dissolved in a nonreactive solvent is contacted with a sulfonating agent at between about -100.degree. C. and +100.degree. C. for a period of time sufficient to result in sulfonation of the elastomeric polymer wherein the improvement includes the use of a sulfonating agent which is formed from mixtures of acyl sulfate ##STR1## with carboxylic acid anhydrides ##STR2## with carboxylic acid halides ##STR3## or with both, wherein R is selected from the group consisting of CH.sub.3 --, C.sub.2 H.sub.5 --, C.sub.3 H.sub.7 --, C.sub.4 H.sub.9 --, C.sub.5 H.sub.11, C.sub.6 H.sub.13 or C.sub.6 H.sub.5 and mixtures thereof. The molar ratio of ##STR4## is at least one.

Abstract: This invention relates to extrusion and injection moldable type elastomeric compositions having a viscosity at 200.degree. C. at 0.73 sec.sup.-1 of about 8.times.10.sup.4 to about 8.times.10.sup.5 poises. The compositions used for elastomeric articles include 100 parts of a neutralized sulfonated EPDM terpolymer; about 25 to about 150 parts per hundred of a non-polar process oil; about 50 to about 300 parts per hundred of a filler; and a preferential plasticizer at about 0 to about 50 parts per hundred based on 100 parts of the sulfonated elastomeric polymer. The composition may also include a crystalline polyolefinic thermoplastic at less than about 100 parts per hundred by weight.These blend compositions can be readily processed due to their superior rheological properties on conventional plastic fabrication equipment into elastomeric articles having excellent physical properties and desirable rubbery characteristics.

Abstract: This invention relates to injection moldable type elastomeric compositions having a viscosity at 200.degree. C. at 0.73 sec.sup.-1 of less than about 8.times.10.sup.4 poises. The compositions used for elastomeric articles include 100 parts of a neutralized sulfonated EPDM terpolymer; about 25 to about 150 parts per hundred of a non-polar process oil; about 25 to about 200 parts per hundred of a filler; and a preferential plasticizer at about less than 50 parts per hundred based on 100 parts of the sulfonated elastomeric polymer. The composition may also include a crystalline polyolefinic thermoplastic at least than about 100 parts per hundred by weight.These blend compositions can be readily processed due to their superior rheological properties on conventional plastic fabrication equipment, especially on low pressure injection molding equipment into elastomeric articles having excellent physical properties and desirable rubbery characteristics.

Abstract: A bulk sulfonation process for the preparation of sulfonated polymers from hydrocarbon polymers having olefinic unsaturation or aromatic moieties, or both, includes intimately mixing the polymer by mechanical means in the absence of a solvent for the polymers with a sulfonation reagent at a sufficient temperature and time to effect the desired degree of sulfonation. The sulfonated polymer may be recovered as the free sulfonic acid or neutralized ionically with a basic compound. Sulfonated polymers including a substantial proportion of aromatic moieties yield water-soluble or water-dispersible salts, useful as thickening and flocculating agents, when neutralized with ammonia monobasic cations or lower alkyl amines. These materials, however, when sulfonated at a low level, e.g. <10 mole SO.sub.3 per mole aromatic, behave like water insensitive thermoplastics.

Abstract: This invention relates to injection moldable and extrusion type elastomeric compositions having a viscosity at 200.degree. C. at 0.73 sec.sup.-1 of less than about 8.times.10.sup.5 poises. The compositions used for elastomeric articles include 100 parts of a neutralized sulfonated EPDM terpolymer; less than about 200 parts per hundred of a paraffinic, low polarity process oil; about 25 to about 200 parts per hundred of an amorphous silica filler treated or untreated; and a preferential plasticizer at about less than 50 parts per hundred based on 100 parts of the sulfonated elastomeric polymer. The composition may also include a crystalline polyolefinic thermoplastic at less than about 100 parts per hundred by weight per 100 parts of sulfonated polymer.

Abstract: This invention relates to a process for first preparing a free flowing finely divided powder of a neutralized sulfonated elastomer and subsequently and optionally admixing said formed powder with other agents such as fillers and oils thereby providing free flowing powders capable of being subsequently fabricated into tough elastomeric objects. The neutralized sulfonated elastomeric polymer can be converted into a free flowing finely divided powder which does not agglomerate or cold flow under ambient conditions by a variety of processes, preferably by a grinding process conducted at low temperatures. The formed powder of the neutralized sulfonated elastomeric polymer is blended with at least one chemical additive into a homogeneous mixture, wherein the chemical additive is selected from the group including fillers, polyolefinic thermoplastics, non-polar backbone process oils, lubricants or a metallic oxide and mixtures thereof.

Abstract: The present invention relates to a process for improving the melt processability and properties of metal neutralized sulfonated polymers by the use of a reactive plasticizer wherein the plasticizer improves the flow of the ionic polymer during processing, and subsequently is polymerized by a free radical process into a thermoset polymer. The resultant composition is an intimate blend of ionic polymer with a thermoset polymer, wherein the resultant composition has improved properties.

Abstract: The instant invention relates to a method for making processable ionic polymer compositions which are characterized as being processable at high temperatures, for example, 200.degree. C, while retaining adequate physical properties at both room temperatures and elevated temperatures which are below the processing temperature, for example, up to 100.degree. C and more. In this method, an ionic polymer comprising an elastomeric or plastic backbone and pendant acid groups is combined with a first neutralizing agent having two components. One component of said neutralizing agent is a metal or ammonium type moiety which combines with the pendant acid groups as a metal or ammonium salt thereof; the other component of neutralizing agent takes up the hydrogen ion present in the pendant acid groups and is converted into a preferential plasticizer for said ionomer.

Abstract: This invention relates to processable ionic elastomer compositions having improved compression set properties, especially at elevated temperatures. In this invention an intractable ionic elastomer, for example, a sulfonated elastomer is blended with from 10 to 70 parts per hundred of a crystalline polyolefin to yield novel compositions having the above properties. Preferably the ionic elastomer is a sulfonated ethylene propylene terpolymer having from about 0.2 to 20 mole percent sulfonate groups, at least 95% of which are combined with counterions selected from the group consisting of Groups IA, IIA, IB, and IIB of the Periodic Table of Elements, aluminum, antimony, lead, and mixtures thereof. The sulfonated polymer is combined with said counterions by neutralization of a polysulfonic acid precurser with a basic material in which the desired counterion is present as the cation thereof.

Abstract: This invention relates to blends of sulfonated elastomers with crystalline polyolefins. The sulfonated elastomer comprises from about 0.2 to about 20 mole percent sulfonate groups, at least 95% of which are combined with metal counter ions selected from the group consisting of Groups I and II of the Periodic Table of the Elements, aluminum, and lead; organic amines; and mixtures thereof. The crystalline polyolefin is preferably selected from the group consisting of polyethylene, including high and low density polyethylenes, and polypropylene. The crystalline polyolefin comprises a minor portion of said blends.