Title of Invention	A CROSSLINKABLE RUBBER COMPOSITION, THE USE THEREOF, THE RUBBER GRAINS THEREFROM, AND A METHOD FOR PREPARING AND INJECTION MOLDING THE RUBBER GRAINS
Abstract	The present invention relates to a crosslinkable rubber composition, the use thereof, the rubber grains therefrom, and a method for preparing and injection molding the rubber grains. This crosslinkable rubber composition includes at least a styrene butadiene copolymer, a softener for rubber, a flow modifier and a peroxide vulcanizing agent. The crosslinkable rubber composition is suitable for being made into rubber products. It can be made into rubber grains that will not crosslink below a temperature of 80?. The rubber grains are formed through internal mixing, open mixing and pelleting extrusion. The rubber composition and the rubber grains of the present invention, having good fluidity and allowing after vulcanization, can be formed directly by injection molding and kept at room temperature over a long period of time.

Title of Invention

A CROSSLINKABLE RUBBER COMPOSITION, THE USE THEREOF, THE RUBBER GRAINS THEREFROM, AND A METHOD FOR PREPARING AND INJECTION MOLDING THE RUBBER GRAINS

Abstract

The present invention relates to a crosslinkable rubber composition, the use thereof, the rubber grains therefrom, and a method for preparing and injection molding the rubber grains. This crosslinkable rubber composition includes at least a styrene butadiene copolymer, a softener for rubber, a flow modifier and a peroxide vulcanizing agent. The crosslinkable rubber composition is suitable for being made into rubber products. It can be made into rubber grains that will not crosslink below a temperature of 80?. The rubber grains are formed through internal mixing, open mixing and pelleting extrusion. The rubber composition and the rubber grains of the present invention, having good fluidity and allowing after vulcanization, can be formed directly by injection molding and kept at room temperature over a long period of time.

Full Text	FORM 2 THE PATENTS ACT 1970 (39 of 1970) & The Patents Rules, 2003 COMPLETE SPECIFICATION (See section 10 and rule 13) 1. A CROSSLINKABLE RUBBER COMPOSITION, THE USE THEREOF, THE RUBBER GRAINS THEREFROM, AND A METHOD FOR PREPARING AND INJECTION MOLDING THE RUBBER GRAINS 2. 1. (A) Shanghai Drb&tafu Industry CO.,Ltd. (B) China (C) Building 2, No.1132, Maoting road, Songjiang Industrial Park, Songjiang District, Shanghai 201600, China The following specification particularly describes the invention and the manner in which it is to be performed. FIELD OF THE INVENTION The present invention, belonging to the rubber manufacturing technical field, relates to a rubber composition, and particularly to a vulcanizible rubber composition that can be kept at room temperature over a long period of time as well as the rubber grains therefrom. BACKGROUND OF THE INVENTION Rubber is an important macromolecular elastomer material, and considerably used in various products, such as tires, shoe soles, seal rings, and various protection devices. The materials used for various products are required to be good in abrasion resistance, flex resistance, water/oil resistance, and heat/cold resistance, high in flexibility and tear strength, and also low in the cost, with a complicated forming process. Various rubber products are mainly made from combination of the following various rubber materials: Natural rubber, isoprene rubber, butadiene rubber, styrene butadiene rubber, nitrile butadiene rubber, neoprene rubber, ethylene propylene terpolymer rubber, and so on. Various traditional rubber materials, being high in molecular weight and poor in fluidity, can be formed only by compression molding. Besides, steam heating is adopted in the vulcanized process of rubber for improving uniformity of the mold temperature; however, this process requires a complicated and expensive high pressure boiler, which is high in equipment investment and energy consumption. The traditional rubber has a high molecular weight and a high level of entanglement among the molecules thereof, which makes the rubber generate a great deal of heat in the process of open mixing or internal mixing; besides, the heat is not easy to be dissipated, making the stock incline to be vulcanized partly, thus making the products after compression molding have defects. Moreover, the stock that is vulcanized with the traditional sulphur may be self-vulcanized at a slightly higher environmental temperature, and thus cannot be stored over a long period of time; a low temperature environment is needed if a long-term storage is desired. It is because of various shortcomings of the traditional rubber that the thermoplastic elastomer is produced, the main of which is styrene series of elastomer. The styrene series of elastomer can be formed by injection molding through a simple manufacturing process and recovered, and is thus fully developed; however, since the styrene series of elastomer keeps the mechanical properties only through physical junctions, it cannot satisfy the requirements of some products for high performance (such as high abrasion resistance, or high tear strength). Furthermore, the styrene series of thermoplastic elastomer is very difficult to effect effective chemical crosslinking, because the styrene series of thermoplastic elastomer is a block copolymer of various segments with different difficulty level of crosslinking, which makes crosslinking nonuniform. SUMMARY OF THE INVENTION For overcoming the various shortcomings of the existing rubber materials and their processes, a purpose of the present invention is to provide a crosslinkable rubber composition, the use thereof, the rubber grains therefrom, and a method for preparing and injection molding the rubber grains, and to allow the rubber composition and the rubber grains to be formed directly by injection molding; besides, the rubber grains will not be self-vulcanized at a temperature below 80?, and can be kept at a temperature of 30? over a long period of time, having no need for low-temperture storage. The following technical solution is adopted to achieve the purpose of the present invention and to solve the technical problems to be solved therein. A crosslinkable rubber composition presented according to the present invention comprises the following components: 40-70 phr of styrene butadiene copolymers, 10-30 phr of flow modifiers, 10-50 phr of softening oil, and 0.1-1 phr of vulcanizing agents. In another embodiment, the crosslinkable rubber composition as described above further contains 1-30 phr of reclaimed materials. The following technical means can also be adopted to further achieve the purpose of the present invention and solve the technical problems to be solved therein. In the rubber composition as described above, the styrene butadiene copolymer has a linear or multiple-arm star-shaped molecular structure, the molecular chain structure being a completely atactic copolymer structure of styrenic monomers and diene monomers or an alternating micro-block structure formed by the multiple block copolymerization of styrenic monomers and diene monomers, content of the 1,2-structure in the diene structure being 10-40%; the molecular structural formula of the styrene butadiene copolymer is -(PSX-PBY)n- or (-(PSX-PBY)n)MR, with the former being of a linear structure while the latter of a multiple-arm star-shaped structure, where PS is a styrenic polymer, PB a diene polymer, R the “core” of the star-shaped structure, X a positive integer in the range of 1-300, Y a positive integer in the range of 1-2000, n a positive integer in the range of 10-3000, and M a positive integer in the range of 3-20; the weight percent content of the styrenic monomer in this styrene butadiene copolymer is 5-80%, with molecular weight of the copolymer being 40000-500000. In the rubber composition as described above, the flow modifier thereof can be selected from at least one of styrene-butadiene-styrene copolymer, styrene-ethylene-butene-styrene copolymer and styrene-ethylene-propylene-styrene copolymer. In the rubber composition as described above, the reclaimed materials thereof can be selected from at least one of reclaimed rubber, PE reclaimed materials, EVA reclaimed materials and PP reclaimed materials. In the rubber composition as described above, the softening oil thereof can be selected from at least one of naphthenic oil, alkane oil and aromatic hydrocarbon oil. In the rubber composition as described above, the vulcanizing agent thereof can be selected from benzoyl peroxide, bis(para-benzoyl peroxide), di-tert-butyl peroxide, dicumyl peroxide and cumene hydroperoxide. A rubber composition as described above further includes a processing assistant, which is selected from one or more of the following group consisting of a vulcanization accelerator, an aging inhibitor, a mold releasing agent, a reinforcing agent, a flame retardant, a thickening agent, and a detackifier. The present invention provides a rubber product, which includes the rubber composition as described above. The present invention further provides a crosslinkable rubber grain, which is made of the rubber composition as described above. The rubber grains as described above are suitable for injection molding or extrusion molding. These rubber grains will not crosslink at a temperature below 80?. The process for preparing the crosslinkable rubber grains as described above can be selected from the following three processes: A first process for preparing the rubber grains: First the styrene butadiene copolymer, the flow modifier, the reclaimed material and the softening oil in a certain ratio are simultaneously put into an internal mixer to be internally mixed for 10-30 minutes, andthen the vulcanizing agent is added and mixed for 3-10 minutes, with the temperature of the internal mixer being 60-120?; the stock after internal mixing is mixed in an open mixer; tight-milled for 2-20 times before being rolled and sheeted; finally the stock is extruded and pelletized by an extruder at a temperature of 60-110?, and then goes through air circulation cutting or water circulation cutting to get the grains. A second process for preparing the rubber grains: First the flow modifier and the softening oil in a certain ratio are put into an internal mixer to be internally mixed for 5-15 minutes, then the styrene butadiene copolymer and the reclaimed material are added and mixed for 5-15 minutes; the vulcanizing agent is added and mixed for 3-10 minutes, with the temperature of the internal mixer being 60-120?; the stock after internal mixing is mixed in the open mixer; tight-milled for 2-20 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 60-110?, and then goes through air circulation cutting or water circulation cutting to get the grains. A third process for preparing the rubber grains: First the styrene butadiene copolymer, the flow modifier, the reclaimed material and the softening oil in a certain ratio are simultaneously put into an internal mixer to be internally mixed for 8-30 minutes, with the temperature of the internal mixer being 100-160?; then the stock after internal mixing is sheeted in the open mixer and, with the vulcanizing agent added, tight-milled for 10-30 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 60-110?, and then goes through air circulation cutting or water circulation cutting to get the grains. In the preparation process, various processing assistants can be added as required by different products, such as a reaction promotor, a vulcanization accelerator, a vulcanization promotion assistant, an antioxidant, an anti-ultraviolet agent, a foaming agent, an aging inhibitor, a heat stabilizer, a light stabilizer, an ozone stabilizer, a processing aid, a plasticizer, a thickening agent, a blowing agent, dye, pigment, wax, an extender, an organic acid, a polymerization inhibitor, a metal oxide, and an activator such as triethanolamine, polyglycol, hexanetriol and so on, which are known in rubber industry. These rubber assistants are used at a normal dosage, which is especially dependent on the expected use. The normal dosage is for example 0.1 wt% to 50 wt% as required by rubber. The present invention further provides a molded rubber product, which is made of the rubber grains as described above by injection molding. The molded rubber product as described above is made by means of the injection molding method. The molded rubber product as described above is a shoe sole. By adopting the technical solution as described above, the present invention has at least the following advantages and beneficial effects: 1. The rubber composition and rubber grains according to the present invention use the styrene butadiene copolymer whose molecular chain structure is composed of mixed atactic and block segments. Since this copolymer has a low molecular weight, the material is good in fluidity; besides, with the part block structure, the material can still have good mechanical properties at a low molecular weight; furthermore, the micro-block structure will not affect the vulcanization uniformity and can make the material have good mechanical properties even with minor vulcanizing agent, therefore the semi-vulcanized material is easy to be desulfurized and recovered. 2. The rubber composition and rubber grains according to the present invention use the peroxide vulcanizing agent, and allow after vulcanization, with the vulcanization rate easy to be controlled and the vulcanization uniform; besides, the rubber grains will not be self-vulcanized at a temperature below 140?, and can be kept at room temperature over a long period of time, having no need for low-temperture storage. 3. The rubber composition and rubber grains according to the present invention are provided with the reclaimed material, which can effectively lower the cost. Moreover, the reclaimed material, being semi-desulfurized, exists in the form of tiny rubber grains after being mixed with the rubber, which can effectively intensify and flexibilize the rubber. What described above is only a summary of the technical solution of the present invention. Detailed description will be given in the following with reference to preferred embodiments and drawings so as to make the technical means of the present invention more clear to be understood that the technical means can be executed according to contents of the specification, and to make the purposes, features and advantages of the present invention as described above and elsewhere more obvious and easier to be understood. DETAILED DESCRIPTION OF THE EMBODIMENTS For further description of the technical means adopted in the present invention for achieving the intended purpose of the present invention as well as the effects, the crosslinkable rubber composition presented in the present invention, the use thereof, the rubber grains therefrom, and the method for preparing and injection molding the rubber grains will be described in detail in the following with reference to drawings and preferred embodiments in regard to the specific embodiments, steps, features and the effects thereof. A first crosslinkable rubber composition according to the present invention comprises the following components: 40-70 phr of styrene butadiene copolymers, 10-30 phr of flow modifiers, 10-50 phr of softening oil, and 0.1-1 phr of vulcanizing agents. A second crosslinkable rubber composition according to the present invention comprises the following components: 40-70 phr of styrene butadiene copolymers, 10-30 phr of flow modifiers, 10-50 phr of softening oil, 0.1-1 phr of vulcanizing agents, and 1-30 phr of auxiliary loading materials. The above components will be described in detail as follows: The styrene butadiene copolymer as described above has a linear or multiple-arm star-shaped molecular structure, the molecular chain structure being a completely atactic copolymer structure of styrenic monomers and diene monomers or an alternating micro-block structure formed by the multiple block copolymerization of styrenic monomers and diene monomers, content of the 1,2-structure in the diene structure being 10-40%; the molecular structural formula of the styrene butadiene copolymer is -(PSX-PBY)n- or (-(PSX-PBY)n)MR, with the former being of a linear structure while the latter of a multiple-arm star-shaped structure, where PS is a styrenic polymer, PB a diene polymer, R the “core” of the star-shaped structure, X a positive integer in the range of 1-300, Y a positive integer in the range of 1-2000, n a positive integer in the range of 10-3000, and M a positive integer in the range of 3-20; weight percent content of the styrenic monomer in this styrene butadiene copolymer is 5-80%, with molecular weight of the copolymer being 40000-500000. The flow modifier as described above can be selected from at least one of styrene-butadiene-styrene copolymer, styrene-ethylene-butene-styrene copolymer and styrene-ethylene-propylene-styrene copolymer. The softening oil for rubber as described above can be selected from naphthenic oil, alkane oil and aromatic hydrocarbon oil. The vulcanizing agent as described above can be selected from one of the following groups consisting of benzoyl peroxide, bis(para-benzoyl peroxide), di-tert-butyl peroxide, dicumyl peroxide and cumene hydroperoxide. Dicumyl peroxide is preferred. The auxiliary loading material as described above is preferred to be reclaimed material, such as reclaimed rubber, reclaimed PE material, reclaimed EVA material and reclaimed PP material. The auxiliary loading material can also be natural or synthetic rubber, low density polyethylene (PE), ethylene-vinyl acetate copolymer (EVA) and polypropylene (PP). Moreover, according to intended uses, the crosslinkable rubber composition of the present invention can be provided with auxiliary assistances that have been known so far, so long as they will not exert a disadvantageous influence on the purposes of the present invention. The auxiliary assistants, such as a vulcanization accelerator, an aging inhibitor, a mold releasing agent, an intensifier for rubber, an anti-ultraviolet agent, a flame retardant, a thickening agent, a detackifier, a crosslinking assistant, a colorant, a dispersant, an antioxidant, a conductive material and so on, are known in rubber industry. These auxiliary assistants are used at a normal dosage, which is especially dependent on the expected use. The normal dosage is for example 0.1 wt% to 50 wt% as required by the rubber. The intensifier for rubber is used for intensifying the mechanical properties of the crosslinked rubber, such as tensile strength, tear strength and abrasion resistance. The examples of the intensifier for rubber include such carbon black as SRF, GPF, FEF, HAF, ISAF, SAF, FT and MT, the carbon black that receives surface treatment with the silane coupling agent, fine powders of silicic acid, and silicon dioxide. The examples of the silicon dioxide include pyrolytic silicon dioxide and precipitated silicon dioxide. The crosslinkable rubber composition according to the present invention can be used for manufacturing household rubber products, industrial rubber products and medical rubber products. The household rubber products include for example raincoats, shoes or gloves. The industrial rubber products include for example a rubber vibration isolator for automobiles, a rubber vibration isolator for railroads, a rubber vibration isolator for industrial devices, or an earthquake resisting rubber for buildings. The rubber vibration isolator for automobiles includes an engine mounting pad, a pulley absorber, a carburetor mounting pad, a torsional vibration damper, a strut mounting pad, a rubber bush, a snubber rubber, an auxiliary rubber, a spring piece, a shock damper, an air spring, an automobile body mounting pad, a bumper guard, a muffler support, a rubber coupling, a rubber clutch pad, a muffler mounting pad, a sliding bush, a cushion strut bar, a brake, a handbrake, a heat radiator support and a muffler hanger. The rubber vibration isolator for railroads includes a pavement pad, a ballast pad or a rail pad. The rubber vibration isolator for industrial devices incudes for example an expansion joint, a flexible joint, a sleeve or a mounting pad. The industrial rubber products include for example an automobile sealing strip, e.g. a car door sealing strip, a back door sealing strip, a trunk sealing strip, a side sealing strip on top, a sliding door sealing strip, a duct sealing strip, a sliding circular panel sealing strip, a front window sealing strip, a rear window sealing strip, a quarter window sealing strip, a pillar sealing strip, an outside door glass sealing strip, an inside door glass sealing strip, a windshield, a glass sliding track, an outside rear view mirror support, a closed headlight and a closed front upper panel. The industrial rubber products include for example rubber hoses, which include liquid hoses and gas hoses. The medical rubber products include for example syringe tubes, hoses, and infusion tubes. The crosslinkable rubber grains according to the present invention are made of the rubber composition as described above and suitable for injection molding or extrusion molding, and will not crosslink at a temperature below 140?. The present invention will further be explained with reference to the following examples. Example 1: A first method for preparing the rubber grains: The rubber grains are prepared with the following conponents according to the following ratios (phr): Styrene butadiene copolymer 70 phr Styrene-ethylene-butene-styrene block copolymer 10 phr Naphthenic oil 19.9 phr Dicumyl peroxide 0.1 phr There are the following preparation steps: First the styrene butadiene copolymer, the styrene-ethylene-butene-styrene block copolymer and the naphthenic oil in the above ratio are simultaneously put into an internal mixer to be internally mixed for 10 minutes; then the dicumyl peroxide is added and mixed for 3 minutes, with the temperature of the internal mixer being 100?; the stock after internal mixing is mixed in an open mixer, and tight-milled for 2 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 70?, and then goes through air circulation cutting to get the rubber grains of the first example. Example 2 A second method for preparing the rubber grains: The rubber grains are prepared with the following conponents according to the following ratios (phr): Styrene butadiene copolymer 40 phr Styrene-ethylene-butene-styrene block copolymer 20 phr Reclaimed rubber 20 phr Aromatic hydrocarbon oil 19.5 phr Dicumyl peroxide 0.5 phr There are the following preparation steps: First the thestyrene-ethylene-butene-styrene block copolymer and the aromatic hydrocarbon oil in the above ratio are put into an internal mixer to be internally mixed for 5 minutes; then the styrene butadiene copolymer and the reclaimed rubber are added and mixed for 10 minutes; then the dicumyl peroxide is added and mixed for 5 minutes, with the temperature of the internal mixer being 80?; the stock after internal mixing is mixed in an open mixer, and tight-milled for 5 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 60?, and then goes through air circulation cutting to get the rubber grains of the second example. Example 3 A third method for preparing the rubber grains: The rubber grains are prepared with the following conponents according to the following ratios (phr): Styrene butadiene copolymer 60 phr Styrene-ethylene-butene-styrene block copolymer 10 phr Reclaimed PP 10 phr Naphthenic oil 19 phr Dicumyl peroxide 1 phr There are the following preparation steps: First the styrene butadiene copolymer, the styrene-ethylene-butene-styrene block copolymer, the reclaimed PP and the naphthenic oil in the above ratio are simultaneously put into an internal mixer to be internally mixed for 20 minutes, with the temperature of the internal mixer being 160?;then the stock after internal mixing is sheeted in the open mixer and, with the dicumyl peroxide added, tight-milled for 30 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 110?, and then goes through water circulation cutting to get the rubber grains of the third example. Example 4 A fourth method for preparing the rubber grains: The rubber grains are prepared with the following conponents according to the following ratios (phr): Styrene butadiene copolymer 55 phr Styrene-ethylene-butene-styrene block copolymer 15 phr Naphthenic oil 29.7 phr Dicumyl peroxide 0.3 phr There are the following preparation steps: First the styrene butadiene copolymer, the styrene-ethylene-butene-styrene block copolymer and the naphthenic oil in the above ratio are simultaneously put into an internal mixer to be internally mixed for 10 minutes; then the dicumyl peroxide is added and mixed for 3 minutes, with the temperature of the internal mixer being 100?; the stock after internal mixing is mixed in an open mixer, and tight-milled for 10 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 70?, and then goes through air circulation cutting to get the rubber grains of the fourth example. Example 5 A fifth method for preparing the rubber grains: The rubber grains are prepared with the following conponents according to the following ratios (phr): Styrene butadiene copolymer 40 phr Styrene-ethylene-butene-styrene block copolymer 9.5 phr Naphthenic oil 50 phr Dicumyl peroxide 0.5 phr There are the following preparation steps: First the styrene butadiene copolymer, the styrene-ethylene-butene-styrene block copolymer and the naphthenic oil in the above ratio are simultaneously put into an internal mixer to be internally mixed for 10 minutes; then the dicumyl peroxide is added and mixed for 3 minutes, with the temperature of the internal mixer being 100?; the stock after internal mixing is mixed in an open mixer, and tight-milled for 10 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 70?, and then goes through air circulation cutting to get the rubber grains of the fifth example. In the preparation processes for each example as described above, various processing assistants can be added as required by properties of different products, such as a vulcanization accelerator, an aging inhibitor, a mold releasing agent, a reinforcing agent, a flame retardant, a thickening agent and a detackifier. Property test of rubber products The rubber grains prepared in each example are formed by injection molding with an injection molding machine to produce a sheet. The mold of the injection molding machine is provided with a heating arrangement, which can keep the mold at a temperature of 100-200?. The test data are as shown in Table 1. Talbe 1. Property test results of the rubber products made of the rubber grains of the present invention Test item Test standard Test result Example 1 Example 2 Example 3 Example 4 Example 5 Melt index (g/10 min) ASTM D1238 11.4 42.8 20.3 15.1 65 Tensile strength (MPa) ASTM D638-98 8.12 5.22 6.38 7.71 4.30 Elongation at break (%) ASTM D638-98 1953 1338 827 1987 1620 Permanent compression deformation (%) ASTM D935 5.3 7.2 9.6 6.2 6.5 Note: ? Conditions for testing the melt index: 200? and 5 Kg, without a vulcanizing agent. ? Conditions for preparing the sample: the injection temperature of 70? and the vulcanization temperature of 165?, with the vulcanization duration of 300 seconds. It can be seen from the above test data that the melt indexes of all the rubber grains are over 10 g/10 min, indicating that fluidity of the grains fully fulfills the requirement of injection molding; all the materials have higher elongation at break, indicating that the rubber after vulcanization has good tenacity; and all the materials have smaller permanent compression deformation, indicating that the rubber has better resilience, high flexibility and high tenacity, as well as certain strength, fully fulfilling the requirements of the rubber material. The crosslinkable rubber grains according the present invention can be kept at a temperature of 35? over a long period of time, having no need for low-temperture storage. The present invention further provides methods for injection molding the rubber grains as described above. A first injection molding method includes the following steps: These rubber grains are heated and pressurized into a turbulent stock at a temperature of 50-120? and a pressure of 50-130 MPa; this turbulent stock is injected into the mold cavity; and the turbulent stock in this mold cavity is vulcanized at a vulcanization temperature of 140-190?, with the vulcanization duration no longer than 10 minutes. A second injection molding method includes the following steps: Three kinds of rubber grains with different ratios are heated and pressurized into three kinds of turbulent stocks, respectively, at a temperature of 50-120? and a pressure of 50-130 MPa; these three kinds of turbulent stocks with different ratios are injected into three noncommunicating mold cavities, respectively; then the early vulcanization is performed to vulcanize the turbulent stocks in these three noncommunicating mold cavities at a vulcanization temperature of 140-190? and a vulcanization duration of 0-120 s; the middle moldboard among the three mold cavities is removed while the other two moldboards at both sides of the middle moldboard are buckled, making two of the three mold cavities communicate with the other mold cavity to form a complete mold cavity; and the turbulent stock in this complete mold cavity is vulcanized at a vulcanization temperature of 140-190? and a vulcanization duration of 100-360s. The injection molding methods as described above are designed for a single kind of rubber grains and three kinds of rubber grains, respectively. Person skilled in the art can further deduce a method of injection molding two kinds of rubber grains with different ratios. This injection molding method is similar to the second injection molding method, with the difference only in that there are two kinds of rubber grains and the corresponding mold has only two mold cavities. The different ratios as described above can be different in the colorant, such as black rubber grains, blue rubber grains and red rubber grains. The color can also be other colors, such as yellow, green, white, purple and so on. The second injection molding method as described above can be used to integratedly mold products of different colors. The crosslinkable rubber grains according to the present invention can be used for preparing the molded rubber products. Further description will be made with reference to the following examples. Example 5 of molded rubber products Firstly, the rubber grains are prepared according to Example 3; and then a shoe sole is made by means of the first injection molding method. A property test is made on the shoe sole, with the results as shown in Table 2. Table 2. Property test results of the shoe soles made of different materials Material Test item Example 5 PU material TR material Rubber Test standard Density, g/cm3 1.02 0.6 1.06 1.26 SATRA 134: 1998 Heat/scald resistance (300?) No damage Severe melt Severe melt No damage SATRA TM49: 1995 Slip resistance Dry 0.72 0.32 0.69 0.87 SATRA TM144: 2006 Wet 0.62 0.30 0.46 0.57 Abrasion, mm3 93 148 401 332 SATRA TM174: 1994 Flex resistance, (5000 cycles) No crack No crack No crack No crack SATRA TM218: 1999 Tear strength, N/mm Lengthwise 6.6 8.6 17.0 4.6 SATRA TM218: 1999 Crosswise 7.8 13.5 17.8 Tensile strength, MPa Lengthwise 9.8 10.0 5.5 Crosswise 8.2 7.7 5.4 4.8 Elongation at break, % Lengthwise 628 468 592 SATRA TM137: 1995 Crosswise 704 316 668 512 It can be seen from the above test data that the shoe sole made by injection molding of the rubber grains of the present invention, compared with the shoe sole made of conventional materials, has higher elongation at break, tear strength and tensile strength, as well as good slip resistance and heat/scald resistance. The rubber composition and rubber grains of the present invention can fulfill the usage requirements. What described above is rather preferred examples than restrictions on the present invention. Any simple amendment, alteration and equivalent structural change made on the above examples according to the technical substance of the present invention will all fall within the scope of protection of the technical solution of the present invention. We Claim:- 1. A crosslinkable rubber composition, characterized in that: it includes 40-70 phr of a styrene butadiene copolymer, 10-50 phr of a softening oil for rubber, 10-30 phr of a flow modifier, and 0.1-1 phr of a peroxide vulcanizing agent. 2. The rubber composition according to claim 1, characterized in that: it further includes 1-30 phr of a reclaimed material that is selected from at least one of reclaimed rubber, PE reclaimed materials, EVA reclaimed materials and PP reclaimed materials. 3. The rubber composition according to claim 1 or 2, characterized in that: the styrene butadiene copolymer thereof has a linear or multiple-arm star-shaped molecular structure, the molecular chain structure being a completely atactic copolymer structure of styrenic monomers and diene monomers or an alternating micro-block structure formed by multiple block copolymerization of the styrenic monomers and the diene monomers, content of the 1,2-structure in the diene structure being 10-40%; the molecular structural formula of the styrene butadiene copolymer is -(PSX-PBY)n- or (-(PSX-PBY)n)MR, with the former being of a linear structure while the latter of a multiple-arm star-shaped structure, where PS is a styrenic polymer, PB a diene polymer, R a “core” of the star-shaped structure, X a positive integer in the range of 1-300, Y a positive integer in the range of 1-2000, n a positive integer in the range of 10-3000, and M a positive integer in the range of 3-20; the weight percent content of the styrenic monomer in this styrene butadiene copolymer is 5-80%, with molecular weight of the copolymer being 40000-500000. 4. The rubber composition according to claim 1 or 2, characterized in that: the flow modifier thereof can be selected from at least one of styrene-butadiene-styrene copolymer, styrene-ethylene-butene-styrene copolymer and styrene-ethylene-propylene-styrene copolymer. 5. The rubber composition according to claim 1 or 2, characterized in that: the softening oil for rubber thereof can be selected from at least one of naphthene oil, alkane oil and aromatic hydrocarbon oil. 6. The rubber composition according to claim 1 or 2, characterized in that: the vulcanizing agent thereof can be selected from the following group consisting of benzoyl peroxide, bis(para-benzoyl peroxide), di-tert-butyl peroxide, dicumyl peroxide and cumene hydroperoxide. 7. The rubber composition according to any of claims 1-6, characterized in that: it further includes an auxiliary assistant. 8. The rubber composition according to claim 7, characterized in that: the auxiliary assistant thereof is selected from one or more of the following group consisting of a vulcanization accelerator, an aging inhibitor, a mold releasing agent, a reinforcing agent, a flame retardant, a thickening agent and a detackifier. 9. A rubber product, characterized in that: it is made of the rubber composition according to any of claims 1-8. 10. The rubber product according to claim 9, characterized in that: it includes raincoats, shoes or gloves. 11. The rubber product according to claim 9, characterized in that: it includes a rubber vibration isolator for automobiles, a rubber vibration isolator for railroads, a rubber vibration isolator for industrial devices or an earthquake resisting rubber for buildings. 12. The rubber product according to claim 11, characterized in that: the rubber vibration isolator for automobiles thereof includes an engine mounting pad, a liquid seal engine bearing mounting pad, a pulley absorber, a chain wheel absorber, a carburetor mounting pad, a torsional vibration damper, a strut mounting pad, a rubber bush, a snubber rubber, an auxiliary rubber, a spring piece, a shock damper, an air spring, an automobile body mounting pad, a bumper guard, a muffler support, a rubber coupling, a central bearing support, a rubber clutch pad, a muffler mounting pad, a suspension bush,a sliding bush, a cushion strut bar, a brake, a handbrake, a heat radiator support, and a muffler hanger. 13. The rubber product according to claim 11, characterized in that: the rubber vibration isolator for railroads thereof includes a pavement pad, a ballast pad or a rail pad. 14. The rubber product according to claim 11, characterized in that: the rubber vibration isolator for industrial devices thereof incudes an expansion joint, a flexible joint, a sleeve or a mounting pad. 15. The rubber product according to claim 9, characterized in that: the rubber product thereof includes an automobile sealing strip. 16. The use according to claim 15, characterized in that: the automobile sealing strip thereof includes a car door sealing strip, a back door sealing strip, a trunk sealing strip, a side sealing strip on top, a sliding door sealing strip, a duct sealing strip, a sliding circular panel sealing strip, a front window sealing strip, a rear window sealing strip, a quarter window sealing strip, a pillar sealing strip, an outside door glass sealing strip, an inside door glass sealing strip, a windshield, a glass sliding track, an outside rear view mirror support, a closed headlight and a closed front upper panel. 17. The rubber product according to claim 9, characterized in that: it includes a medical apparatus. 18. A crosslinkable rubber grain, characterized in that: it comprises the rubber composition according to any of claims 1-8. 19. The rubber grain according to claim 18, characterized in that: it is suitable for injection molding or extrusion molding. 20. The rubber grain according to claim 18, characterized in that: it will not crosslink at a temperature below 80?. 21. A method for preparing the rubber grain according to claim 18, characterized in that: it includes the following steps: first the styrene butadiene copolymer, the flow modifier, the reclaimed material and the soft oil are simultaneously put into an internal mixer to be internally mixed for 10-30 minutes; then the vulcanizing agent is added and mixed for 3-10 minutes, with the temperature of the internal mixer being 60-120?; the stock after internal mixing is mixed in an open mixer, and tight-milled for 2-20 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 60-110?, and then goes through air circulation cutting or water circulation cutting to get the grains. 22. A method for preparing the rubber grain according to claim 18, characterized in that: it includes the following steps: first the flow modifier and the soft oil are put into an internal mixer to be internally mixed and mixed for 5-15 minutes; then the styrene butadiene copolymer and the reclaimed material are added and mixed for 5-15 minutes; then the vulcanizing agent is added and mixed for 3-6 minutes, with the temperature of the internal mixer being 60-120?; the stock after internal mixing is mixed in an open mixer, and tight-milled for 2-20 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 60-110?, and then goes through air circulation cutting or water circulation cutting to get the grains. 23. A method for preparing the rubber grain according to claim 18, characterized in that: it includes the following steps: first the styrene butadiene copolymer, the flow modifier, the reclaimed material and the soft oil are simultaneously put into an internal mixer to be internally mixed for 10-30 minutes, with the temperature of the internal mixer being 100-160?; then the stock after internal mixing is sheeted in an open mixer and, with the vulcanizing agent added, tight-milled for 10-20 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 60-110?, and then goes through air circulation cutting or water circulation cutting to get the grains. 24. An injection molding method for preparing the rubber grain according to claim 18, characterized in that: it includes the following steps: the rubber grains are heated and pressurized into a turbulent stock at a temperature of 50-120? and a pressure of 50-130 MPa; the turbulent stock is injected into a mold cavity; and the turbulent stock in this mold cavity is vulcanized at a vulcanization temperature of 140-190? and a vulcanization duration of 1-10 minutes. 25. An injection molding method for preparing the rubber grain according to claim 18, characterized in that: it includes the following steps: three kinds of rubber grains with different ratios are heated and pressurized into three kinds of turbulent stocks, respectively, at a temperature of 50-120? and a pressure of 50-130 MPa; the three kinds of turbulent stocks with different ratios are injected into three noncommunicating mold cavities, respectively; a middle moldboard among the three mold cavities is removed while the other two moldboards at both sides of the middle moldboard are buckled, making two of the three mold cavities communicate with the other mold cavity to form a complete mold cavity; and the turbulent stock in this complete mold cavity is vulcanized at a vulcanization temperature of 140-190? and a vulcanization duration of 100-360s. 26. A molded rubber product, characterized in that: it is prepared by injection molding of the rubber grain according to claim 9. 27. The molded rubber product according to claim 26, characterized in that: it is prepared by the injection molding method according to claim 24. 28. The molded rubber product according to claim 26, characterized in that: it is prepared by the injection molding method according to claim 25. 29. The molded rubber product according to any of claims 26-28, characterized in that: it includes a shoe sole. Dated this 1st day of September, 2011.

Full Text

FORM 2
THE PATENTS ACT 1970
(39 of 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)

1. A CROSSLINKABLE RUBBER COMPOSITION, THE USE THEREOF, THE RUBBER GRAINS THEREFROM, AND A METHOD FOR PREPARING AND INJECTION MOLDING THE RUBBER GRAINS

2.

1. (A) Shanghai Drb&tafu Industry CO.,Ltd.
(B) China
(C) Building 2, No.1132, Maoting road, Songjiang Industrial Park, Songjiang
District, Shanghai 201600, China

The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF THE INVENTION
The present invention, belonging to the rubber manufacturing technical field, relates to a rubber composition, and particularly to a vulcanizible rubber composition that can be kept at room temperature over a long period of time as well as the rubber grains therefrom.

BACKGROUND OF THE INVENTION
Rubber is an important macromolecular elastomer material, and considerably used in various products, such as tires, shoe soles, seal rings, and various protection devices. The materials used for various products are required to be good in abrasion resistance, flex resistance, water/oil resistance, and heat/cold resistance, high in flexibility and tear strength, and also low in the cost, with a complicated forming process. Various rubber products are mainly made from combination of the following various rubber materials: Natural rubber, isoprene rubber, butadiene rubber, styrene butadiene rubber, nitrile butadiene rubber, neoprene rubber, ethylene propylene terpolymer rubber, and so on. Various traditional rubber materials, being high in molecular weight and poor in fluidity, can be formed only by compression molding. Besides, steam heating is adopted in the vulcanized process of rubber for improving uniformity of the mold temperature; however, this process requires a complicated and expensive high pressure boiler, which is high in equipment investment and energy consumption. The traditional rubber has a high molecular weight and a high level of entanglement among the molecules thereof, which makes the rubber generate a great deal of heat in the process of open mixing or internal mixing; besides, the heat is not easy to be dissipated, making the stock incline to be vulcanized partly, thus making the products after compression molding have defects. Moreover, the stock that is vulcanized with the traditional sulphur may be self-vulcanized at a slightly higher environmental temperature, and thus cannot be stored over a long period of time; a low temperature environment is needed if a long-term storage is desired. It is because of various shortcomings of the traditional rubber that the thermoplastic elastomer is produced, the main of which is styrene series of elastomer. The styrene series of elastomer can be formed by injection molding through a simple manufacturing process and recovered, and is thus fully developed; however, since the styrene series of elastomer keeps the mechanical properties only through physical junctions, it cannot satisfy the requirements of some products for high performance (such as high abrasion resistance, or high tear strength). Furthermore, the styrene series of thermoplastic elastomer is very difficult to effect effective chemical crosslinking, because the styrene series of thermoplastic elastomer is a block copolymer of various segments with different difficulty level of crosslinking, which makes crosslinking nonuniform.

SUMMARY OF THE INVENTION
For overcoming the various shortcomings of the existing rubber materials and their processes, a purpose of the present invention is to provide a crosslinkable rubber composition, the use thereof, the rubber grains therefrom, and a method for preparing and injection molding the rubber grains, and to allow the rubber composition and the rubber grains to be formed directly by injection molding; besides, the rubber grains will not be self-vulcanized at a temperature below 80?, and can be kept at a temperature of 30? over a long period of time, having no need for low-temperture storage.
The following technical solution is adopted to achieve the purpose of the present invention and to solve the technical problems to be solved therein. A crosslinkable rubber composition presented according to the present invention comprises the following components: 40-70 phr of styrene butadiene copolymers, 10-30 phr of flow modifiers, 10-50 phr of softening oil, and 0.1-1 phr of vulcanizing agents.
In another embodiment, the crosslinkable rubber composition as described above further contains 1-30 phr of reclaimed materials.
The following technical means can also be adopted to further achieve the purpose of the present invention and solve the technical problems to be solved therein.
In the rubber composition as described above, the styrene butadiene copolymer has a linear or multiple-arm star-shaped molecular structure, the molecular chain structure being a completely atactic copolymer structure of styrenic monomers and diene monomers or an alternating micro-block structure formed by the multiple block copolymerization of styrenic monomers and diene monomers, content of the 1,2-structure in the diene structure being 10-40%; the molecular structural formula of the styrene butadiene copolymer is -(PSX-PBY)n- or (-(PSX-PBY)n)MR, with the former being of a linear structure while the latter of a multiple-arm star-shaped structure, where PS is a styrenic polymer, PB a diene polymer, R the “core” of the star-shaped structure, X a positive integer in the range of 1-300, Y a positive integer in the range of 1-2000, n a positive integer in the range of 10-3000, and M a positive integer in the range of 3-20; the weight percent content of the styrenic monomer in this styrene butadiene copolymer is 5-80%, with molecular weight of the copolymer being 40000-500000.
In the rubber composition as described above, the flow modifier thereof can be selected from at least one of styrene-butadiene-styrene copolymer, styrene-ethylene-butene-styrene copolymer and styrene-ethylene-propylene-styrene copolymer.
In the rubber composition as described above, the reclaimed materials thereof can be selected from at least one of reclaimed rubber, PE reclaimed materials, EVA reclaimed materials and PP reclaimed materials.
In the rubber composition as described above, the softening oil thereof can be selected from at least one of naphthenic oil, alkane oil and aromatic hydrocarbon oil.
In the rubber composition as described above, the vulcanizing agent thereof can be selected from benzoyl peroxide, bis(para-benzoyl peroxide), di-tert-butyl peroxide, dicumyl peroxide and cumene hydroperoxide.
A rubber composition as described above further includes a processing assistant, which is selected from one or more of the following group consisting of a vulcanization accelerator, an aging inhibitor, a mold releasing agent, a reinforcing agent, a flame retardant, a thickening agent, and a detackifier.
The present invention provides a rubber product, which includes the rubber composition as described above.
The present invention further provides a crosslinkable rubber grain, which is made of the rubber composition as described above.
The rubber grains as described above are suitable for injection molding or extrusion molding. These rubber grains will not crosslink at a temperature below 80?.
The process for preparing the crosslinkable rubber grains as described above can be selected from the following three processes:
A first process for preparing the rubber grains: First the styrene butadiene copolymer, the flow modifier, the reclaimed material and the softening oil in a certain ratio are simultaneously put into an internal mixer to be internally mixed for 10-30 minutes, andthen the vulcanizing agent is added and mixed for 3-10 minutes, with the temperature of the internal mixer being 60-120?; the stock after internal mixing is mixed in an open mixer; tight-milled for 2-20 times before being rolled and sheeted; finally the stock is extruded and pelletized by an extruder at a temperature of 60-110?, and then goes through air circulation cutting or water circulation cutting to get the grains.
A second process for preparing the rubber grains: First the flow modifier and the softening oil in a certain ratio are put into an internal mixer to be internally mixed for 5-15 minutes, then the styrene butadiene copolymer and the reclaimed material are added and mixed for 5-15 minutes; the vulcanizing agent is added and mixed for 3-10 minutes, with the temperature of the internal mixer being 60-120?; the stock after internal mixing is mixed in the open mixer; tight-milled for 2-20 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 60-110?, and then goes through air circulation cutting or water circulation cutting to get the grains.
A third process for preparing the rubber grains: First the styrene butadiene copolymer, the flow modifier, the reclaimed material and the softening oil in a certain ratio are simultaneously put into an internal mixer to be internally mixed for 8-30 minutes, with the temperature of the internal mixer being 100-160?; then the stock after internal mixing is sheeted in the open mixer and, with the vulcanizing agent added, tight-milled for 10-30 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 60-110?, and then goes through air circulation cutting or water circulation cutting to get the grains.
In the preparation process, various processing assistants can be added as required by different products, such as a reaction promotor, a vulcanization accelerator, a vulcanization promotion assistant, an antioxidant, an anti-ultraviolet agent, a foaming agent, an aging inhibitor, a heat stabilizer, a light stabilizer, an ozone stabilizer, a processing aid, a plasticizer, a thickening agent, a blowing agent, dye, pigment, wax, an extender, an organic acid, a polymerization inhibitor, a metal oxide, and an activator such as triethanolamine, polyglycol, hexanetriol and so on, which are known in rubber industry. These rubber assistants are used at a normal dosage, which is especially dependent on the expected use. The normal dosage is for example 0.1 wt% to 50 wt% as required by rubber.
The present invention further provides a molded rubber product, which is made of the rubber grains as described above by injection molding.
The molded rubber product as described above is made by means of the injection molding method.
The molded rubber product as described above is a shoe sole.
By adopting the technical solution as described above, the present invention has at least the following advantages and beneficial effects:
1. The rubber composition and rubber grains according to the present invention use the styrene butadiene copolymer whose molecular chain structure is composed of mixed atactic and block segments. Since this copolymer has a low molecular weight, the material is good in fluidity; besides, with the part block structure, the material can still have good mechanical properties at a low molecular weight; furthermore, the micro-block structure will not affect the vulcanization uniformity and can make the material have good mechanical properties even with minor vulcanizing agent, therefore the semi-vulcanized material is easy to be desulfurized and recovered.
2. The rubber composition and rubber grains according to the present invention use the peroxide vulcanizing agent, and allow after vulcanization, with the vulcanization rate easy to be controlled and the vulcanization uniform; besides, the rubber grains will not be self-vulcanized at a temperature below 140?, and can be kept at room temperature over a long period of time, having no need for low-temperture storage.
3. The rubber composition and rubber grains according to the present invention are provided with the reclaimed material, which can effectively lower the cost. Moreover, the reclaimed material, being semi-desulfurized, exists in the form of tiny rubber grains after being mixed with the rubber, which can effectively intensify and flexibilize the rubber.
What described above is only a summary of the technical solution of the present invention. Detailed description will be given in the following with reference to preferred embodiments and drawings so as to make the technical means of the present invention more clear to be understood that the technical means can be executed according to contents of the specification, and to make the purposes, features and advantages of the present invention as described above and elsewhere more obvious and easier to be understood.

DETAILED DESCRIPTION OF THE EMBODIMENTS
For further description of the technical means adopted in the present invention for achieving the intended purpose of the present invention as well as the effects, the crosslinkable rubber composition presented in the present invention, the use thereof, the rubber grains therefrom, and the method for preparing and injection molding the rubber grains will be described in detail in the following with reference to drawings and preferred embodiments in regard to the specific embodiments, steps, features and the effects thereof.
A first crosslinkable rubber composition according to the present invention comprises the following components: 40-70 phr of styrene butadiene copolymers, 10-30 phr of flow modifiers, 10-50 phr of softening oil, and 0.1-1 phr of vulcanizing agents.
A second crosslinkable rubber composition according to the present invention comprises the following components: 40-70 phr of styrene butadiene copolymers, 10-30 phr of flow modifiers, 10-50 phr of softening oil, 0.1-1 phr of vulcanizing agents, and 1-30 phr of auxiliary loading materials.
The above components will be described in detail as follows:
The styrene butadiene copolymer as described above has a linear or multiple-arm star-shaped molecular structure, the molecular chain structure being a completely atactic copolymer structure of styrenic monomers and diene monomers or an alternating micro-block structure formed by the multiple block copolymerization of styrenic monomers and diene monomers, content of the 1,2-structure in the diene structure being 10-40%; the molecular structural formula of the styrene butadiene copolymer is -(PSX-PBY)n- or (-(PSX-PBY)n)MR, with the former being of a linear structure while the latter of a multiple-arm star-shaped structure, where PS is a styrenic polymer, PB a diene polymer, R the “core” of the star-shaped structure, X a positive integer in the range of 1-300, Y a positive integer in the range of 1-2000, n a positive integer in the range of 10-3000, and M a positive integer in the range of 3-20; weight percent content of the styrenic monomer in this styrene butadiene copolymer is 5-80%, with molecular weight of the copolymer being 40000-500000.
The flow modifier as described above can be selected from at least one of styrene-butadiene-styrene copolymer, styrene-ethylene-butene-styrene copolymer and styrene-ethylene-propylene-styrene copolymer.
The softening oil for rubber as described above can be selected from naphthenic oil, alkane oil and aromatic hydrocarbon oil.
The vulcanizing agent as described above can be selected from one of the following groups consisting of benzoyl peroxide, bis(para-benzoyl peroxide), di-tert-butyl peroxide, dicumyl peroxide and cumene hydroperoxide. Dicumyl peroxide is preferred.
The auxiliary loading material as described above is preferred to be reclaimed material, such as reclaimed rubber, reclaimed PE material, reclaimed EVA material and reclaimed PP material. The auxiliary loading material can also be natural or synthetic rubber, low density polyethylene (PE), ethylene-vinyl acetate copolymer (EVA) and polypropylene (PP).
Moreover, according to intended uses, the crosslinkable rubber composition of the present invention can be provided with auxiliary assistances that have been known so far, so long as they will not exert a disadvantageous influence on the purposes of the present invention.
The auxiliary assistants, such as a vulcanization accelerator, an aging inhibitor, a mold releasing agent, an intensifier for rubber, an anti-ultraviolet agent, a flame retardant, a thickening agent, a detackifier, a crosslinking assistant, a colorant, a dispersant, an antioxidant, a conductive material and so on, are known in rubber industry. These auxiliary assistants are used at a normal dosage, which is especially dependent on the expected use. The normal dosage is for example 0.1 wt% to 50 wt% as required by the rubber.
The intensifier for rubber is used for intensifying the mechanical properties of the crosslinked rubber, such as tensile strength, tear strength and abrasion resistance. The examples of the intensifier for rubber include such carbon black as SRF, GPF, FEF, HAF, ISAF, SAF, FT and MT, the carbon black that receives surface treatment with the silane coupling agent, fine powders of silicic acid, and silicon dioxide. The examples of the silicon dioxide include pyrolytic silicon dioxide and precipitated silicon dioxide.
The crosslinkable rubber composition according to the present invention can be used for manufacturing household rubber products, industrial rubber products and medical rubber products.
The household rubber products include for example raincoats, shoes or gloves.
The industrial rubber products include for example a rubber vibration isolator for automobiles, a rubber vibration isolator for railroads, a rubber vibration isolator for industrial devices, or an earthquake resisting rubber for buildings. The rubber vibration isolator for automobiles includes an engine mounting pad, a pulley absorber, a carburetor mounting pad, a torsional vibration damper, a strut mounting pad, a rubber bush, a snubber rubber, an auxiliary rubber, a spring piece, a shock damper, an air spring, an automobile body mounting pad, a bumper guard, a muffler support, a rubber coupling, a rubber clutch pad, a muffler mounting pad, a sliding bush, a cushion strut bar, a brake, a handbrake, a heat radiator support and a muffler hanger. The rubber vibration isolator for railroads includes a pavement pad, a ballast pad or a rail pad. The rubber vibration isolator for industrial devices incudes for example an expansion joint, a flexible joint, a sleeve or a mounting pad.
The industrial rubber products include for example an automobile sealing strip, e.g. a car door sealing strip, a back door sealing strip, a trunk sealing strip, a side sealing strip on top, a sliding door sealing strip, a duct sealing strip, a sliding circular panel sealing strip, a front window sealing strip, a rear window sealing strip, a quarter window sealing strip, a pillar sealing strip, an outside door glass sealing strip, an inside door glass sealing strip, a windshield, a glass sliding track, an outside rear view mirror support, a closed headlight and a closed front upper panel.
The industrial rubber products include for example rubber hoses, which include liquid hoses and gas hoses.
The medical rubber products include for example syringe tubes, hoses, and infusion tubes.
The crosslinkable rubber grains according to the present invention are made of the rubber composition as described above and suitable for injection molding or extrusion molding, and will not crosslink at a temperature below 140?.
The present invention will further be explained with reference to the following examples.

Example 1:
A first method for preparing the rubber grains:
The rubber grains are prepared with the following conponents according to the following ratios (phr):
Styrene butadiene copolymer 70 phr
Styrene-ethylene-butene-styrene block copolymer 10 phr
Naphthenic oil 19.9 phr
Dicumyl peroxide 0.1 phr
There are the following preparation steps: First the styrene butadiene copolymer, the styrene-ethylene-butene-styrene block copolymer and the naphthenic oil in the above ratio are simultaneously put into an internal mixer to be internally mixed for 10 minutes; then the dicumyl peroxide is added and mixed for 3 minutes, with the temperature of the internal mixer being 100?; the stock after internal mixing is mixed in an open mixer, and tight-milled for 2 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 70?, and then goes through air circulation cutting to get the rubber grains of the first example.

Example 2
A second method for preparing the rubber grains:
The rubber grains are prepared with the following conponents according to the following ratios (phr):
Styrene butadiene copolymer 40 phr
Styrene-ethylene-butene-styrene block copolymer 20 phr
Reclaimed rubber 20 phr
Aromatic hydrocarbon oil 19.5 phr
Dicumyl peroxide 0.5 phr
There are the following preparation steps: First the thestyrene-ethylene-butene-styrene block copolymer and the aromatic hydrocarbon oil in the above ratio are put into an internal mixer to be internally mixed for 5 minutes; then the styrene butadiene copolymer and the reclaimed rubber are added and mixed for 10 minutes; then the dicumyl peroxide is added and mixed for 5 minutes, with the temperature of the internal mixer being 80?; the stock after internal mixing is mixed in an open mixer, and tight-milled for 5 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 60?, and then goes through air circulation cutting to get the rubber grains of the second example.

Example 3
A third method for preparing the rubber grains:
The rubber grains are prepared with the following conponents according to the following ratios (phr):
Styrene butadiene copolymer 60 phr
Styrene-ethylene-butene-styrene block copolymer 10 phr
Reclaimed PP 10 phr
Naphthenic oil 19 phr
Dicumyl peroxide 1 phr
There are the following preparation steps: First the styrene butadiene copolymer, the styrene-ethylene-butene-styrene block copolymer, the reclaimed PP and the naphthenic oil in the above ratio are simultaneously put into an internal mixer to be internally mixed for 20 minutes, with the temperature of the internal mixer being 160?;then the stock after internal mixing is sheeted in the open mixer and, with the dicumyl peroxide added, tight-milled for 30 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 110?, and then goes through water circulation cutting to get the rubber grains of the third example.

Example 4
A fourth method for preparing the rubber grains:
The rubber grains are prepared with the following conponents according to the following ratios (phr):
Styrene butadiene copolymer 55 phr
Styrene-ethylene-butene-styrene block copolymer 15 phr
Naphthenic oil 29.7 phr
Dicumyl peroxide 0.3 phr
There are the following preparation steps: First the styrene butadiene copolymer, the styrene-ethylene-butene-styrene block copolymer and the naphthenic oil in the above ratio are simultaneously put into an internal mixer to be internally mixed for 10 minutes; then the dicumyl peroxide is added and mixed for 3 minutes, with the temperature of the internal mixer being 100?; the stock after internal mixing is mixed in an open mixer, and tight-milled for 10 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 70?, and then goes through air circulation cutting to get the rubber grains of the fourth example.

Example 5
A fifth method for preparing the rubber grains:
The rubber grains are prepared with the following conponents according to the following ratios (phr):
Styrene butadiene copolymer 40 phr
Styrene-ethylene-butene-styrene block copolymer 9.5 phr
Naphthenic oil 50 phr
Dicumyl peroxide 0.5 phr
There are the following preparation steps: First the styrene butadiene copolymer, the styrene-ethylene-butene-styrene block copolymer and the naphthenic oil in the above ratio are simultaneously put into an internal mixer to be internally mixed for 10 minutes; then the dicumyl peroxide is added and mixed for 3 minutes, with the temperature of the internal mixer being 100?; the stock after internal mixing is mixed in an open mixer, and tight-milled for 10 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 70?, and then goes through air circulation cutting to get the rubber grains of the fifth example.
In the preparation processes for each example as described above, various processing assistants can be added as required by properties of different products, such as a vulcanization accelerator, an aging inhibitor, a mold releasing agent, a reinforcing agent, a flame retardant, a thickening agent and a detackifier.

Property test of rubber products
The rubber grains prepared in each example are formed by injection molding with an injection molding machine to produce a sheet. The mold of the injection molding machine is provided with a heating arrangement, which can keep the mold at a temperature of 100-200?. The test data are as shown in Table 1.
Talbe 1. Property test results of the rubber products
made of the rubber grains of the present invention
Test item Test standard Test result
Example 1 Example 2 Example 3 Example 4 Example 5
Melt index
(g/10 min) ASTM D1238 11.4 42.8 20.3 15.1 65
Tensile strength
(MPa) ASTM D638-98 8.12 5.22 6.38 7.71 4.30
Elongation at break
(%) ASTM D638-98 1953 1338 827 1987 1620
Permanent compression deformation
(%) ASTM D935 5.3 7.2 9.6 6.2 6.5
Note: ? Conditions for testing the melt index: 200? and 5 Kg, without a vulcanizing agent.
? Conditions for preparing the sample: the injection temperature of 70? and the vulcanization temperature of 165?, with the vulcanization duration of 300 seconds.
It can be seen from the above test data that the melt indexes of all the rubber grains are over 10 g/10 min, indicating that fluidity of the grains fully fulfills the requirement of injection molding; all the materials have higher elongation at break, indicating that the rubber after vulcanization has good tenacity; and all the materials have smaller permanent compression deformation, indicating that the rubber has better resilience, high flexibility and high tenacity, as well as certain strength, fully fulfilling the requirements of the rubber material.
The crosslinkable rubber grains according the present invention can be kept at a temperature of 35? over a long period of time, having no need for low-temperture storage.
The present invention further provides methods for injection molding the rubber grains as described above.
A first injection molding method includes the following steps: These rubber grains are heated and pressurized into a turbulent stock at a temperature of 50-120? and a pressure of 50-130 MPa; this turbulent stock is injected into the mold cavity; and the turbulent stock in this mold cavity is vulcanized at a vulcanization temperature of 140-190?, with the vulcanization duration no longer than 10 minutes.
A second injection molding method includes the following steps: Three kinds of rubber grains with different ratios are heated and pressurized into three kinds of turbulent stocks, respectively, at a temperature of 50-120? and a pressure of 50-130 MPa; these three kinds of turbulent stocks with different ratios are injected into three noncommunicating mold cavities, respectively; then the early vulcanization is performed to vulcanize the turbulent stocks in these three noncommunicating mold cavities at a vulcanization temperature of 140-190? and a vulcanization duration of 0-120 s; the middle moldboard among the three mold cavities is removed while the other two moldboards at both sides of the middle moldboard are buckled, making two of the three mold cavities communicate with the other mold cavity to form a complete mold cavity; and the turbulent stock in this complete mold cavity is vulcanized at a vulcanization temperature of 140-190? and a vulcanization duration of 100-360s.
The injection molding methods as described above are designed for a single kind of rubber grains and three kinds of rubber grains, respectively. Person skilled in the art can further deduce a method of injection molding two kinds of rubber grains with different ratios. This injection molding method is similar to the second injection molding method, with the difference only in that there are two kinds of rubber grains and the corresponding mold has only two mold cavities.
The different ratios as described above can be different in the colorant, such as black rubber grains, blue rubber grains and red rubber grains. The color can also be other colors, such as yellow, green, white, purple and so on.
The second injection molding method as described above can be used to integratedly mold products of different colors.
The crosslinkable rubber grains according to the present invention can be used for preparing the molded rubber products. Further description will be made with reference to the following examples.
Example 5 of molded rubber products
Firstly, the rubber grains are prepared according to Example 3; and
then a shoe sole is made by means of the first injection molding method.
A property test is made on the shoe sole, with the results as shown in Table 2.
Table 2. Property test results of the shoe soles made of different materials
Material
Test item Example 5 PU material TR material Rubber Test standard
Density, g/cm3 1.02 0.6 1.06 1.26 SATRA 134: 1998
Heat/scald resistance (300?) No damage Severe melt Severe melt No damage SATRA TM49: 1995
Slip resistance Dry 0.72 0.32 0.69 0.87 SATRA TM144: 2006
Wet 0.62 0.30 0.46 0.57
Abrasion, mm3 93 148 401 332 SATRA TM174: 1994
Flex resistance, (5000 cycles) No crack No crack No crack No crack SATRA TM218: 1999
Tear strength, N/mm Lengthwise 6.6 8.6 17.0 4.6 SATRA TM218: 1999
Crosswise 7.8 13.5 17.8
Tensile strength, MPa Lengthwise 9.8 10.0 5.5
Crosswise 8.2 7.7 5.4 4.8
Elongation at break, % Lengthwise 628 468 592 SATRA TM137: 1995
Crosswise 704 316 668 512

It can be seen from the above test data that the shoe sole made by injection molding of the rubber grains of the present invention, compared with the shoe sole made of conventional materials, has higher elongation at break, tear strength and tensile strength, as well as good slip resistance and heat/scald resistance. The rubber composition and rubber grains of the present invention can fulfill the usage requirements.
What described above is rather preferred examples than restrictions on the present invention. Any simple amendment, alteration and equivalent structural change made on the above examples according to the technical substance of the present invention will all fall within the scope of protection of the technical solution of the present invention.

We Claim:-
1. A crosslinkable rubber composition, characterized in that: it includes 40-70 phr of a styrene butadiene copolymer, 10-50 phr of a softening oil for rubber, 10-30 phr of a flow modifier, and 0.1-1 phr of a peroxide vulcanizing agent.
2. The rubber composition according to claim 1, characterized in that: it further includes 1-30 phr of a reclaimed material that is selected from at least one of reclaimed rubber, PE reclaimed materials, EVA reclaimed materials and PP reclaimed materials.
3. The rubber composition according to claim 1 or 2, characterized in that: the styrene butadiene copolymer thereof has a linear or multiple-arm star-shaped molecular structure, the molecular chain structure being a completely atactic copolymer structure of styrenic monomers and diene monomers or an alternating micro-block structure formed by multiple block copolymerization of the styrenic monomers and the diene monomers, content of the 1,2-structure in the diene structure being 10-40%; the molecular structural formula of the styrene butadiene copolymer is -(PSX-PBY)n- or (-(PSX-PBY)n)MR, with the former being of a linear structure while the latter of a multiple-arm star-shaped structure, where PS is a styrenic polymer, PB a diene polymer, R a “core” of the star-shaped structure, X a positive integer in the range of 1-300, Y a positive integer in the range of 1-2000, n a positive integer in the range of 10-3000, and M a positive integer in the range of 3-20; the weight percent content of the styrenic monomer in this styrene butadiene copolymer is 5-80%, with molecular weight of the copolymer being 40000-500000.
4. The rubber composition according to claim 1 or 2, characterized in that: the flow modifier thereof can be selected from at least one of styrene-butadiene-styrene copolymer, styrene-ethylene-butene-styrene copolymer and styrene-ethylene-propylene-styrene copolymer.
5. The rubber composition according to claim 1 or 2, characterized in that: the softening oil for rubber thereof can be selected from at least one of naphthene oil, alkane oil and aromatic hydrocarbon oil.
6. The rubber composition according to claim 1 or 2, characterized in that: the vulcanizing agent thereof can be selected from the following group consisting of benzoyl peroxide, bis(para-benzoyl peroxide), di-tert-butyl peroxide, dicumyl peroxide and cumene hydroperoxide.
7. The rubber composition according to any of claims 1-6, characterized in that: it further includes an auxiliary assistant.
8. The rubber composition according to claim 7, characterized in that: the auxiliary assistant thereof is selected from one or more of the following group consisting of a vulcanization accelerator, an aging inhibitor, a mold releasing agent, a reinforcing agent, a flame retardant, a thickening agent and a detackifier.
9. A rubber product, characterized in that: it is made of the rubber composition according to any of claims 1-8.
10. The rubber product according to claim 9, characterized in that: it includes raincoats, shoes or gloves.
11. The rubber product according to claim 9, characterized in that: it includes a rubber vibration isolator for automobiles, a rubber vibration isolator for railroads, a rubber vibration isolator for industrial devices or an earthquake resisting rubber for buildings.
12. The rubber product according to claim 11, characterized in that: the rubber vibration isolator for automobiles thereof includes an engine mounting pad, a liquid seal engine bearing mounting pad, a pulley absorber, a chain wheel absorber, a carburetor mounting pad, a torsional vibration damper, a strut mounting pad, a rubber bush, a snubber rubber, an auxiliary rubber, a spring piece, a shock damper, an air spring, an automobile body mounting pad, a bumper guard, a muffler support, a rubber coupling, a central bearing support, a rubber clutch pad, a muffler mounting pad, a suspension bush,a sliding bush, a cushion strut bar, a brake, a handbrake, a heat radiator support, and a muffler hanger.
13. The rubber product according to claim 11, characterized in that: the rubber vibration isolator for railroads thereof includes a pavement pad, a ballast pad or a rail pad.
14. The rubber product according to claim 11, characterized in that: the rubber vibration isolator for industrial devices thereof incudes an expansion joint, a flexible joint, a sleeve or a mounting pad.
15. The rubber product according to claim 9, characterized in that: the rubber product thereof includes an automobile sealing strip.
16. The use according to claim 15, characterized in that: the automobile sealing strip thereof includes a car door sealing strip, a back door sealing strip, a trunk sealing strip, a side sealing strip on top, a sliding door sealing strip, a duct sealing strip, a sliding circular panel sealing strip, a front window sealing strip, a rear window sealing strip, a quarter window sealing strip, a pillar sealing strip, an outside door glass sealing strip, an inside door glass sealing strip, a windshield, a glass sliding track, an outside rear view mirror support, a closed headlight and a closed front upper panel.
17. The rubber product according to claim 9, characterized in that: it includes a medical apparatus.
18. A crosslinkable rubber grain, characterized in that: it comprises the rubber composition according to any of claims 1-8.
19. The rubber grain according to claim 18, characterized in that: it is suitable for injection molding or extrusion molding.
20. The rubber grain according to claim 18, characterized in that: it will not crosslink at a temperature below 80?.
21. A method for preparing the rubber grain according to claim 18, characterized in that: it includes the following steps: first the styrene butadiene copolymer, the flow modifier, the reclaimed material and the soft oil are simultaneously put into an internal mixer to be internally mixed for 10-30 minutes; then the vulcanizing agent is added and mixed for 3-10 minutes, with the temperature of the internal mixer being 60-120?; the stock after internal mixing is mixed in an open mixer, and tight-milled for 2-20 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 60-110?, and then goes through air circulation cutting or water circulation cutting to get the grains.
22. A method for preparing the rubber grain according to claim 18, characterized in that: it includes the following steps: first the flow modifier and the soft oil are put into an internal mixer to be internally mixed and mixed for 5-15 minutes; then the styrene butadiene copolymer and the reclaimed material are added and mixed for 5-15 minutes; then the vulcanizing agent is added and mixed for 3-6 minutes, with the temperature of the internal mixer being 60-120?; the stock after internal mixing is mixed in an open mixer, and tight-milled for 2-20 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 60-110?, and then goes through air circulation cutting or water circulation cutting to get the grains.
23. A method for preparing the rubber grain according to claim 18, characterized in that: it includes the following steps: first the styrene butadiene copolymer, the flow modifier, the reclaimed material and the soft oil are simultaneously put into an internal mixer to be internally mixed for 10-30 minutes, with the temperature of the internal mixer being 100-160?; then the stock after internal mixing is sheeted in an open mixer and, with the vulcanizing agent added, tight-milled for 10-20 times before being rolled and sheeted; and finally the stock is extruded and pelletized by an extruder at a temperature of 60-110?, and then goes through air circulation cutting or water circulation cutting to get the grains.
24. An injection molding method for preparing the rubber grain according to claim 18, characterized in that: it includes the following steps:
the rubber grains are heated and pressurized into a turbulent stock at a temperature of 50-120? and a pressure of 50-130 MPa;
the turbulent stock is injected into a mold cavity; and
the turbulent stock in this mold cavity is vulcanized at a vulcanization temperature of 140-190? and a vulcanization duration of 1-10 minutes.
25. An injection molding method for preparing the rubber grain according to claim 18, characterized in that: it includes the following steps:
three kinds of rubber grains with different ratios are heated and pressurized into three kinds of turbulent stocks, respectively, at a temperature of 50-120? and a pressure of 50-130 MPa;
the three kinds of turbulent stocks with different ratios are injected into three noncommunicating mold cavities, respectively;
a middle moldboard among the three mold cavities is removed while the other two moldboards at both sides of the middle moldboard are buckled, making two of the three mold cavities communicate with the other mold cavity to form a complete mold cavity; and
the turbulent stock in this complete mold cavity is vulcanized at a vulcanization temperature of 140-190? and a vulcanization duration of 100-360s.
26. A molded rubber product, characterized in that: it is prepared by injection molding of the rubber grain according to claim 9.
27. The molded rubber product according to claim 26, characterized in that: it is prepared by the injection molding method according to claim 24.
28. The molded rubber product according to claim 26, characterized in that: it is prepared by the injection molding method according to claim 25.
29. The molded rubber product according to any of claims 26-28, characterized in that: it includes a shoe sole.

Dated this 1st day of September, 2011.

Documents:

http://ipindiaonline.gov.in/patentsearch/GrantedSearch/viewdoc.aspx?id=tFKOMCEDkF3XWGbI2RmgKQ==&loc=vsnutRQWHdTHa1EUofPtPQ==

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Patent Number

270021

Indian Patent Application Number

1808/MUMNP/2011

PG Journal Number

48/2015

Publication Date

27-Nov-2015

Grant Date

24-Nov-2015

Date of Filing

01-Sep-2011

Name of Patentee

Shanghai Drb&tafu Industry CO. Ltd.

Applicant Address

Building 2 No.1132 Maoting road Songjiang Industrial Park Songjiang District Shanghai 201600 China

Inventors:

#	Inventor's Name	Inventor's Address
1	SunYong Ye	Room 1701 Huameng Business Palace Bus Station Avenue Lucheng District Wenzhou Zhejiang 325000 China
2	ShunChao Fu	Room 1701 Huameng Business Palace Bus Station Avenue Lucheng District Wenzhou Zhejiang 325000 China
3	JinZhong Huang	Room 1701 Huameng Business Palace Bus Station Avenue Lucheng District Wenzhou Zhejiang 325000 China
4	XiaoLin Qiu	Room 1701 Huameng Business Palace Bus Station Avenue Lucheng District Wenzhou Zhejiang 325000 China

PCT International Classification Number

C08L 25/10,B29B 7/28

PCT International Application Number

PCT/CN2009/000850

PCT International Filing date

2009-07-30

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1	200910047435.0	2009-03-10	China
2	200910150291.1	2009-06-26	China