Processing promoters - keys to successful compounding.The goal of this article is to provide a better understanding and appreciation of processing promoters. It is hoped that by explaining how processing promoters function and showing a few examples, you will feel more comfortable in selecting and using them. In the broadest definition, a processing promoter is a chemical that facilitates or, indeed, makes possible the production and processing of rubber compounds. Specifically, a good processing promoter should be able to improve mixing and processing characteristics of a rubber stock, and preferably improve physical properties of the vulcanizate, without changing cure behavior. Over the long history of the rubber industry, as mixing or processing problems presented themselves, solutions were found empirically, i.e., a `try this, try that' approach. Through this trial and error process and good observations, certain chemicals were found that produced the desired changes. It was found that the different problems could be grouped into categories and the chemicals that solved these problems could likewise be grouped into families. Table 1 summarizes the families of chemicals that produce certain effects. This article will focus on mastication mastication /mas·ti·ca·tion/ (mas?ti-ka´shun) chewing; the biting and grinding of food. mastication (mas´tikā´sh aids, dispersants, lubricants lubricants preparations for the lubrication of passages to reduce frictional injury, e.g. oily preparations, including petroleum jelly, lanolin or water-soluble preparations such as methyl cellulose. and homogenizers.
Table 1 - processing promoters according to
their effect
Effect Examples
Mastication aids Pentachlorothiophenol and its
Zinc salts
Diaryldisulfides
Dispersants Fatty acids
(internal lubricants) Metal soaps
Fatty acid esters
Fatty alcohols
Lubricants Metal soaps
(external lubricants) Fatty acid esters
Fatty acid amides
Low mw hydrocarbons
Homogenizers Hydrocarbon resins
Fatty acid derivatives
Bitumen
Tackifiers Phenolic resins
Coumarone-indene resins
Hydrocarbon resins
Reinforcing agents Phenolic resins
Assembling agents Factice (vulcanized vegetable oil)
Table 1 shows that the same chemicals are listed for both dispersants and lubricants, with the term internal lubricants in parentheses See parenthesis. parentheses - See left parenthesis, right parenthesis. under dispersants, and the term "external lubricants" in parentheses under lubricants. These differences will be explained when we study the theory of processing promoters and amply demonstrated with examples. Theories Lubricity lu·bric·i·ty n. The quality or condition of being lubricious. [Late Latin l bricit theoryThe first is called the lubricity theory in which a polymer matrix is likened to a pile of nonwoven non·wo·ven adj. Made by a process not involving weaving. Used of textiles. n. Material or a fabric made by a process not involving weaving. fibers, somewhat like a piece of felt. The individual fibers are the polymer chains. Because they are randomly oriented o·ri·ent n. 1. Orient The countries of Asia, especially of eastern Asia. 2. a. The luster characteristic of a pearl of high quality. b. A pearl having exceptional luster. 3. and entwined, they are difficult to move. If a plasticizer/lubricant is introduced between the chains, then they become physically separated and can slide past one another more easily; consequently, the whole mass is more deformable. Gel theory In the gel theory, the stiffness of the polymer chain is due to a three-dimensional structure or gel-like network with active sites along the chains serving as hooks between the chains. By adding a plasticizer/lubricant, these points of attraction are masked A state of being disabled or cut off. and there is a swelling of the gel so deforming is made easier. Free-volume theory The free-volume theory proposes that the presence of a plasticizer plas·ti·ciz·er n. Any of various substances added to plastics or other materials to make or keep them soft or pliable. plasticizer or -ciser Noun lowers the glass transition temperature The glass transition temperature is the temperature below which the physical properties of amorphous materials vary in a manner similar to those of a solid phase (glassy state), and above which amorphous materials behave like liquids (rubbery state). of the polymer. In so doing, it increases the free volume of the matrix, which is a function of temperature and structure. In practice, the percentage of any one theory to a given application depends to a large extent on the particular polymer being used. The first theory best describes the case for very nonpolar nonpolar not having poles; not exhibiting dipole characteristics. hydrocarbon hydrocarbon (hī'drōkär`bən), any organic compound composed solely of the elements hydrogen and carbon. The hydrocarbons differ both in the total number of carbon and hydrogen atoms in their molecules and in the proportion of hydrogen polymers like EPM EPM equine protozoal myeloencephalitis. and EPDM EPDM Ethylene-Propylene-Diene-Monomer EPDM Enterprise Product Data Management EPDM Ethylene Propylene Dimonomer (industrial/commercial piping/plumbing components) EPDM Engineering Product Data Management . The second theory would apply to polar polymers like NBR NBR Number NBR Nightly Business Report (PBS show) NBR National Business Review (New Zealand weekly business newspaper) NBR National Bureau of Asian Research NBR National Board of Review and EVM EVM Earned Value Management EVM Evaluation Module EVM Error Vector Magnitude EVM Electronic Voting Machine EVM Expert Group on Vitamins and Minerals EVM Economic Value Management EVM Extraneous Vegetable Matter EVM Extra-Value Meal EVM Electronic Voltmeter , as well as highly unsaturated unsaturated /un·sat·u·rat·ed/ (un-sach´ur-at?ed) 1. not holding all of a solute which can be held in solution by the solvent. 2. denoting compounds in which two or more atoms are united by double or triple bonds. polymers such as NR, SBR SBR - Spectral Band Replication , IR, etc. The third theory would apply more to the thermoplastic A polymer material that turns to liquid when heated and becomes solid when cooled. There are more than 40 types of thermoplastics, including acrylic, polypropylene, polycarbonate and polyethylene. polymers. The assumption made in all of the theories is that the plasticizer/lubricant ends up between the polymer chains. In layman's terms, this refers to solubility solubility Degree to which a substance dissolves in a solvent to make a solution (usually expressed as grams of solute per litre of solvent). Solubility of one fluid (liquid or gas) in another may be complete (totally miscible; e.g. . Solubility or insolubility in·sol·u·ble adj. 1. That cannot be dissolved: insoluble matter. 2. Difficult or impossible to solve or explain; insolvable: insoluble riddles. of the processing promoter in the polymer determines its function on the mixing and processing characteristics of the compound. This relationship between solubility and performance can be described as follows: Polymer soluble soluble /sol·u·ble/ (sol´u-b'l) susceptible of being dissolved. sol·u·ble adj. Capable of being dissolved, especially easily dissolved. processing promoters are known as internal lubricants. They swell and lubricate lu·bri·cate v. lu·bri·cat·ed, lu·bri·cat·ing, lu·bri·cates v.tr. 1. To apply a lubricant to. 2. To make slippery or smooth. v.intr. To act as a lubricant. the polymer chains, thus facilitating dispersion dispersion, in chemistry dispersion, in chemistry, mixture in which fine particles of one substance are scattered throughout another substance. A dispersion is classed as a suspension, colloid, or solution. of ingredients. Polymer insoluble insoluble /in·sol·u·ble/ (in-sol´u-b'l) not susceptible of being dissolved. in·sol·u·ble adj. Not soluble. processing promoters are known as external lubricants. They tend to migrate to the surface of the compound, thus facilitating release from metal surfaces such as mill rolls or mixer mixer, either of two electronic devices in which two or more signals are combined. In the type of mixer used in radio receivers, radar receivers, and similar systems, a signal is translated upward or downward in frequency. rotors, and improve extrusion and injection molding injection molding n. A manufacturing process for forming objects, as of plastic or metal, by heating the molding material to a fluid state and injecting it into a mold. characteristics where rubber is sliding over metal surfaces. A processing promoter consisting of a blend of ingredients (Aflux 42M) will be used to show that a given product can perform different functions in different polymers. The function of a processing promoter in any given polymer is determined by its solubility in that polymer, as shown in table 2.
Table 2
EPDM NR CR NBR
Alcohols 0 1 7 7
Fatty acids 2 3 5 8
Esters(*) 2 3 5 10
Total 4 7 17 25
The ratings are from 0 to 10 where 0 means total
insolubility and 10 means total solubility
(*) Esters of fatty alcohols and fatty acids
(**) Pentaerythrityltetrastearate
After summing the relative solubilities of the various components of the processing promoter in the various polymers, it is obvious that it is not very soluble in EPDM, a little more soluble in NR, more soluble in CR and very soluble in NBR. So, theoretically, the processing promoter will behave as a lubricant Lubricant A gas, liquid, or solid used to prevent contact of parts in relative motion, and thereby reduce friction and wear. In many machines, cooling by the lubricant is equally important. in EPDM and even NR, whereas it will perform as a dispersant dis·per·sant n. Chemistry A liquid or gas added to a mixture to promote dispersion or to maintain dispersed particles in suspension. in CR and NBR. Keep in mind that in reality, since most processing promoters are blends, they can do some percentage of both functions simultaneously, the percentage depending on the particular polymer. Mastication Mastication is the process, especially dramatic in the case of natural rubber, in which the higher molecular weight polymer chains are broken into smaller units to reduce the "nerve" of the rubber, lower the viscosity, and improve flow properties. This process can be carried out using either mechanical shear shear: see strength of materials. Shear A straining action wherein applied forces produce a sliding or skewing type of deformation. or a combination of mechanical shear and chemical peptizers. Mechanical mastication Mechanical mastication yields a homogeneous The same. Contrast with heterogeneous. homogeneous - (Or "homogenous") Of uniform nature, similar in kind. 1. In the context of distributed systems, middleware makes heterogeneous systems appear as a homogeneous entity. For example see: interoperable network. and smooth rubber compound with good flow properties that produces a vulcanizate with good physical properties. However, mechanical mastication takes a long time and requires a lot of energy. Chemical mastication using peptizers Some commercially available chemical peptizers include (a) activated pentachlorothiophenol; (b) the zinc salt of pentachlorothiophenol; (c) di-o-benzamidophenyl disulfide di·sul·fide n. A chemical compound containing two sulfur atoms combined with other elements or radicals. Also called bisulfide. ; (d) zinc 2-benzamidothiophenate; (e) activated mixtures of fatty acids fatty acid, any of the organic carboxylic acids present in fats and oils as esters of glycerol. Molecular weights of fatty acids vary over a wide range. The carbon skeleton of any fatty acid is unbranched. Some fatty acids are saturated, i.e. , soaps of fatty acids and fatty alcohols fatty alcohol n. Any of various alcohols derived from plant or animal oils and fats and used in plastics and pharmaceuticals. ; and (f) others. The use of chemical peptizers shortens the required mixing time and generally reduces the total amount of required energy. However, there are several disadvantages associated with the use of chemical peptizers, such as: * Distribution problems with small amounts of peptizer; * masterbatch is not homogeneous; * masterbatch stickier and not easy to process; * SBR and NR/SBR blends tend to form gel. Since these are very powerful chemicals, they are consequently used in small quantities. Because they are used in small quantities and are mixed in short mixing cycles, one frequently experiences distribution and dispersion problems. For example, the masterbatch might not be homogeneous due to undispersed particles of peptizing agent. This leads to "hot spots hot spots acute moist dermatitis. ." The polymer chains immediately surrounding these pockets of chemical peptizer are broken into smaller segments than in the bulk of the mix. These little domains of low MW polymer are tacky. In fact, natural rubber stocks peptized with small concentrations of chemical peptizers are generally more sticky and tacky due to the formation of more low MW fragments. Second, in NR/SBR blends, some of the SBR crosslinks and forms gel. This phenomenon is referred to as cyclization cy·cli·za·tion n. The formation of one or more rings in a hydrocarbon. . To minimize the problems mentioned above, some suppliers of processing promoters used for peptizing natural rubber and NR/SBR blends have developed diluted di·lute tr.v. di·lut·ed, di·lut·ing, di·lutes 1. To make thinner or less concentrated by adding a liquid such as water. 2. To lessen the force, strength, purity, or brilliance of, especially by admixture. forms of these active chemical peptizers. The chemical peptizer is generally dissolved dis·solve v. dis·solved, dis·solv·ing, dis·solves v.tr. 1. To cause to pass into solution: dissolve salt in water. 2. or diluted in a zinc soap, which, as you will see later, is itself a processing promoter. The main advantages of using diluted chemical peptizers are: * Efficient peptization pep·tize tr.v. pep·tized, pep·tiz·ing, pep·tiz·es To disperse (a precipitate) to form a colloid. [Greek peptein, to digest; see pekw- , even at mill temperatures as low as 60 [degrees] C; * reduce mixing time; * facilitate more homogeneous distribution of the active chemical resulting in no hot spots, less surface tackiness and less mold mold, name for certain multicellular organisms of the various classes of the kingdom Fungi, characteristically having bodies composed of a cottony mycelium. The colors of molds are caused by the spores, which are borne on the mycelium. fouling in injection molding; * improve overall flow characteristics of uncured stocks; * facilitate more homogeneous dispersion of fillers/curatives; * eliminate tendency toward cyclization in SBR and NR/SBR blends; * polymer retains higher overall average molecular weight resulting in better carbon black dispersion due to higher shear and overall improvement in physical properties. Table 3 shows the inconsistency in·con·sis·ten·cy n. pl. in·con·sis·ten·cies 1. The state or quality of being inconsistent. 2. Something inconsistent: many inconsistencies in your proposal. of a stock mixed with a chemical peptizer based on activated pentachlorophenol pentachlorophenol a wood preservative with great capacity to enter the body by any route, including percutaneously; causes weight loss, low milk production and general debility. and the homogeneity Homogeneity The degree to which items are similar. of a stock mixed with a diluted chemical peptizer based on an activated zinc soap. After equal mix times of 60 seconds, the viscosity of the stock mixed with the "diluted peptizer" is significantly lower than that mixed with the "pure peptizer." This holds true even as the speed of the internal mixer is increased from 60 rpm to 80 rpm. However, of particular interest, is the variation in viscosity within each batch. The variation in the stock mixed for 60 seconds at 60 rpm with pure peptizer shows a variation of almost 10 Mooney points, whereas the stock mixed under the same set of conditions with the diluted peptizer shows a total variation under four Mooney points. Although the differences become less with more shear, the stock containing the diluted peptizer still shows about half the variation as the stock with the pure peptizer.
Table 3 - peptizing effect of "diluted" versus
"pure" peptizers
The conditions were as follows:
BR laboratory internal mixer
40% fill factor
60 second mix time
Rotor speed: 60 rpm
Ingredients:
SIR 20 natural rubber
0.3 phr "pure" peptizer
2.0 phr "diluted" peptizer
Test procedure:
Each batch passed once through a 1/4" open mill
Each batch cut into 16 pieces
Mooney viscosity at 100 [degrees] C determined on all pieces
from center and edges of "sheeted" batch
Test results (Mooney viscosity at 100 [degrees] C)
Mixed 60 sec. at 60 RPM: Mixed 60 sec. at 80 RPM:
"Pure" "Diluted" "Pure" "Diluted"
61.3 54.2 63.4 53.4
68.3 55.5 63.6 54.1
70.9 58.0 67.0 55.8
Another significant difference is the time to achieve dispersion of the carbon black. Table 4 shows the incorporation rate of carbon black into stocks mixed without processing promoter (only stearic acid stearic acid /ste·a·ric ac·id/ (ste-ar´ik) a saturated 18-carbon fatty acid occurring in most fats and oils, particularly of tropical plants and land animals; used pharmaceutically as a tablet and capsule lubricant and as an emulsifying ), Renacit 7, Aktiplast F and Aktiplast M. As you can see, it took 63 seconds for the carbon black to be incorporated into the stock without processing promoter, 45 seconds for carbon black incorporation into the stock with Renacit 7, 45 seconds for carbon black incorporation into the stock with Aktiplast F, and only 24 seconds for carbon black incorporation into the stock with Aktiplast M. Table 4 - carbon black incorporation as a function of peptizing agent Recipe A B C D SIR 10 96.0 SBR 1516 4.0 Carbon black N-330 60.0 Naphtolen ZD 8.0 Vulkanox 4010 1.2 Vulkanox 4020 0.8 Vulkanox HS 1.0 Antilux 654 1.2 ZnO special 3.0 Vulkacit DOTG 0.2 Vulkacit TMTD 0.2 Vulkacit TBBS 1.0 Sulfur 2.0 Rhenogran CTP-80 0.3 Stearic acid 2.0 1.0 1.0 1.0 Renacit 7 -- 0.2 -- -- Aktiplast F -- -- 2.0 -- Aktiplast M -- -- -- 2.0 Carbon black incorporation 63.0 45.0 45.0 24.0 (seconds) In this study, the polymers were masticated 60 seconds, the ram raised, the carbon black added, the ram closed and the mixing started. As the carbon black was being incorporated into the stock, the viscosity of the stock increased and the power consumption increased. After the carbon black was incorporated into the rubber, the viscosity began to drop and the power consumption began to drop. The time between when the ram was lowered and the time the power consumption curve began to go down was taken as the carbon black incorporation time. The carbon black incorporation times were determined from the power consumption charts shown in figure 1. [ILLUSTRATION OMITTED] Since we have just shown that actuated ac·tu·ate tr.v. ac·tu·at·ed, ac·tu·at·ing, ac·tu·ates 1. To put into motion or action; activate: electrical relays that actuate the elevator's movements. 2. zinc soaps provide faster incorporation time, we will demonstrate the improved properties obtained by this improved carbon black dispersion. To do this, two identical stocks were mixed, one with and one without the activated zinc soap, for each type of carbon black from low surface area to high surface area. The recipe and mix procedure are shown in table 5. The results of the study are shown in table 6.
Table 5 - improving dispersion of high surface
area carbon black using zinc soaps
Recipe:
SMR-20 70
Polybutadiene 30
Carbon black 65
Zinc oxide 3.5
Stearic acid 1.6
6-PPD 1.5
TMQ 1.5
MBS 0.9
Sulfur 1.5
110.4
Mixing procedure:
First cycle: 80 rpm, water on one-half
Load rubber and Aktiplast M (if present) ram down
0' Start time
50" Raise ram, add all ingredients except Santocure
MOR and sulfur
2' Raise ram, sweep, ram down
3-1/2" Raise ram, discharge, pass through open mill
Second cycle: 80 rpm, water off
Load all ingredients, ram down
0' Start time
50" Raise ram, scrape, ram down
1-1/2" Raise ram, discharge, pass through mill
Table 6 - zinc soaps excel in dispersing high
surface area carbon blacks
A A' B B' C C'
Compound 10.4 110.4 110.4 110.4 110.4 110.4
Aktiplast M 2 -- 2 -- 2 --
N-330 65 65 -- -- -- --
N-220 -- -- 65 65 -- --
N-110 -- -- -- -- 65 65
Naphthenic oil 15 16 15 16 15 16
ML 1+4(100 [degrees] C) 89 >200 >200 >200 >200 >200
Cure @ 330 [degrees] F
[T.sub.2] 1.8 1.7 1.8 1.7 1.8 1.9
[T.sub.90] 4.4 4.0 4.7 4.2 4.3 4.3
Minimum 19.3 24.0 23.6 26.7 29.4 32.5
Maximum 79.7 79.0 79.2 75.2 78.4 75.8
Cure 10' @ 330
[degrees] F
Modulus, psi
100% 590 610 750 750 630 720
200% 1,480 1,480 1,750 1,680 1,530 1,500
300% 2,410 2,350 2,760 2,620 2,530 2,410
Tensile psi 3,410 3,270 3,450 3,220 3,650 2,940
Elongation, % 430 420 370 370 430 360
Shore A 71 71 72 71 74 74
Die C [tear.sup.1] 471 450 434 440 432 402
Rebound, % 47 45 42 42 42 42
[sup.1] lbs. f/in.
It is quite obvious in every case that the tensile strength tensile strength Ratio of the maximum load a material can support without fracture when being stretched to the original area of a cross section of the material. When stresses less than the tensile strength are removed, a material completely or partially returns to its values for the stocks containing the activated zinc soap are significantly higher than those for the controls. It is especially noticeable in the case of the N110 carbon black where the processing promoter allowed for the complete and homogeneous distribution of the carbon black, thus facilitating the exceptional properties expected of such a carbon black. One practical use of an activated zinc soap is demonstrated in a typical NR/BR retread re·tread tr.v. re·tread·ed, re·tread·ing, re·treads 1. To fit (a worn automotive tire) with a new tread. 2. stock, shown in table 7. In this very complicated, highly loaded retread stock containing both NR and BR, two different kinds of filler fill·er 1 n. One that fills, as: a. Something added to augment weight or size or fill space. b. A composition, especially a semisolid that hardens on drying, used to fill pores, cracks, or holes in wood, plaster, , and a relatively low level of oil, the use of an activated zinc soap makes it possible to mix this compound in 8.5 minutes using only two passes as opposed to a conventional three pass mix taking 12 minutes.
Table 7 - activated zinc soap in a retread stock
Recipes A B
(3 pass mix) (2 pass mix)
SMR 20 60 60
BR 40 40
Rhenosin 145A 1.5 1.5
Aktiplast M -- 2
Tread black 45.6 45.6
HiSil 18.1 18.1
Stearic acid 2 2
Zinc oxide 4 4
6-PPD 1.5 1.5
TMQ 1.0 1.0
Antilux 654 0.7 0.7
Oil 15 15
TBBS 0.9 0.9
PVI 0.2 0.2
Sulfur 1.5 1.5
Total mix time (min.) 12.0 8.5
ML(1+4) 100 [degrees] C 70 69
Extrusion speed (cm/min.): 102 111
Extrusion output (g/min.): 97 105
300% modulus (MPa): 11.0 11.7
Comparing the physicals of the two stocks, it is obvious that they are very similar. The only apparent difference between the two stocks is that the one mixed with the activated zinc soap has a lower tan delta, which suggests lower heat buildup build·up also build-up n. 1. The act or process of amassing or increasing: a military buildup; a buildup of tension during the strike. 2. and thus better tire life. There are two rules of thumb when using chemical peptizers. First, the chemical peptizer is added to the polymer at the very beginning of the mix cycle. Second, mix as long as possible before introducing the antioxidant antioxidant, substance that prevents or slows the breakdown of another substance by oxygen. Synthetic and natural antioxidants are used to slow the deterioration of gasoline and rubber, and such antioxidants as vitamin C (ascorbic acid), butylated hydroxytoluene . Dispersants and lubricants As you saw earlier, the same families of chemicals that are used as dispersants are also used as lubricants. It is the goal here to show that the basic reason a processing promoter will either function predominantly as a dispersant (internal lubricant) or a lubricant (external lubricant) - (in reality they do some percentage of both simultaneously) - is the solubility of the processing promoter in the base polymer. Solubility is the key to understanding processing promoters. If the chemical is very soluble in the polymer, it dissolves fast, opens the polymer network, and allows faster filler incorporation. The chemical then remains in the bulk of the polymer matrix affecting the viscosity of the compound. On the other hand, if the processing promoter has limited solubility in the polymer, or contains components that have limited solubility in the polymer, then that insoluble portion can bloom to the surface of the rubber stock or to the interface between the rubber and the surfaces of the processing equipment. This gives a lubricating effect between the rubber stock and the parts it contacts, such as metal surfaces of the mixing equipment, extruder dies, injection molding mold surfaces, calender CALENDER. An almanac. Julius Caesar ordained that the Roman year should consist of 365 days, except every fourth year, which should contain 366, the additional day to be reckoned by counting the twenty-fourth day of February (which was the 6th of the calends of March) twice. rolls, etc. Thus, the portion of the processing promoter that blooms to the surface acts as an external lubricant. The portion that dissolves in the rubber stock behaves as an internal lubricant and reduces the viscosity. The combined effect of lower viscosity and greater surface lubricity has a pronounced effect on flow properties. Advantages of using dispersants or internal lubricants include: * Reduced mixing time; * improved carbon black/filler dispersion; * improved dispersion of curatives; * improved batch-to-batch consistency; * reduced compound viscosity; * improved flow characteristics of the compound. Figure 2 clearly shows the advantages of using a good dispersing agent such as a polymer soluble zinc soap of predominantly unsaturated fatty acids unsaturated fatty acids, n.pl the double- or triple-bonded fatty acids contained primarily in vegetable oils and fish, which remain liquid at room temperature; linked to a reduction in the risk of developing heart disease. . [GRAPH OMITTED] It was the custom at a certain rubber company to run a rheometer rhe·om·e·ter n. An instrument for measuring the flow of viscous liquids, such as blood. curve on each batch of stock mixed in the internal mixer. At the end of each shift, all of the rheometer curves would be printed on a single sheet of paper. The set of 25 curves you see at the top are from a period of time when the stocks were mixed without a processing promoter. The set of 25 rheometer curves on the bottom was made after the company started using a processing promoter composed of zinc soaps. This shows a rather dramatic difference in batch-to-batch consistency. This obvious improvement in batch-to-batch consistency provides a number of downstream advantages. External lubricants offer the following advantages: * Higher extrusion rates; * constant extrusion temperature; * lower energy consumption; * extrusions free of pulsations; * higher dimensional stability dimensional stability, n See stability, dimensional. ; * little decrease in viscosity; * smoother surfaces. Table 8 shows a couple of practical examples in which the differences between dispersants and lubricants can clearly be seen. Figure 3 is a comparison between Aflux 12, which has very limited solubility in NBR, and Aktiplast T, a soap, which is totally soluble in NBR. In this example, the Aflux 12 generates an incredible surface lubrication lubrication, introduction of a substance between the contact surfaces of moving parts to reduce friction and to dissipate heat. A lubricant may be oil, grease, graphite, or any substance—gas, liquid, semisolid, or solid—that permits free action of resulting in greatly increased injection molding speed and a much higher loading of the injection spider mold. Aktiplast T, which is totally soluble in NBR, also provides a slight improvement in flow properties over the control, partly due to some of the material being on the surface and partly because of the reduced viscosity of the compound. However, because of its greater solubility in the rubber matrix, it cannot give the same improvement in flow properties as obtained with the Aflux 12. [ILLUSTRATION OMITTED] Table 8 - internal versus external lubricants in NBR Recipe: Perbunan N 3307 100 100 100 Carbon black N-550 65 65 65 Vulkanol 85 10 10 10 Stearic acid 0.5 0.5 0.5 Vulkanox HS 1.5 1.5 1.5 Vulkanox MB 2 1.5 1.5 1.5 Zinkoxyd Aktiv 5 5 5 Sulfur 0.4 0.4 0.4 TMTD 2.5 2.5 2.5 Aktiplast T -- 3 -- Aflux 12 -- -- 3 Mooney viscosity ML(1+4) 100 [degrees] C 85 80 70 Physical properties (cured 10' @ 160 [degrees] C) Hardness (durometer A) 73 70 70 Elasticity (%) 31 30 30 Tear strength (N/mm) 24.4 22.9 27.2 100% modulus (MPa) 4.9 4.1 4.3 300% modulus (MPa) 16.3 13.6 13.8 Tensile strength (MPa) 19.8 20.1 19.1 Elongation at break (%) 400 500 435 Extrusion speed (cm/min.) 118 140 144 Extrusion output(g/min.) 100 125 140 Rheovulkameter (180 [degrees] C/50s/80 bar) IM volume ([mm.sup.3]) 305 580 863 IM speed ([mm.sup.3]/s) 11.3 16.5 24.5 One point worth mentioning is that the tensile strength values have been maintained throughout the entire gamut See color gamut. gamut - The gamut of a monitor is the set of colours it can display. There are some colours which can't be made up of a mixture of red, green and blue phosphor emissions and so can't be displayed by any monitor. of the test series, and percent elongation elongation, in astronomy, the angular distance between two points in the sky as measured from a third point. The elongation of a planet is usually measured as the angular distance from the sun to the planet as measured from the earth. at break values have only slightly changed with the increased levels of plasticizer. If these changes are unsatisfactory, they can be restored by simply removing some of the plasticizer. The most important point to remember from the above discussion is that a processing promoter can behave as an internal lubricant (dispersant) in one polymer and as an external lubricant (lubricant) in another. Thus, it is extremely important to know the nature of the compound you are using and the properties you wish to influence before selecting the processing promoter. Homogenizers Processing promoters that function as homogenizers are composed of chemicals that are compatible with polar and nonpolar polymers. The most efficient homogenizers are typically resins containing aromatic aromatic /ar·o·mat·ic/ (ar?o-mat´ik) 1. having a spicy odor. 2. in chemistry, denoting a compound containing a ring system stabilized by a closed circle of conjugated double bonds or nonbonding electron pairs, e.g. , naphthenic and paraffinic fractions. These processing promoters, when added to a blend of two dissimilar polymers, become the common solvent, if you wish, and thus allow more intimate mixing of the two different polymer phases within the mix. Because of their solubility in the polymers, as you would expect, they greatly improve filler dispersion, especially carbon black dispersion. One can achieve a comparable degree of homogenization homogenization (həmŏj'ənəzā`shən), process in which a mixture is made uniform throughout. Generally this procedure involves reducing the size of the particles of one component of the mixture and dispersing them evenly by using a blend of processing promoters, each being soluble in one of the polymers to be blended, but then there is the risk of blooming A condition with older CCD devices that causes distortion at the pixel level. It occurs when the electrical charge created exceeds the storage capacity of the device and spills over into adjacent pixels. Newer CCDs incorporate anti-blooming circuitry to drain the excess charge. See CCD. . The most common homogenizing agents include low molecular weight resin blends, fatty acid derivatives and products based on bitumen bitumen (bĭty `mən) a generic term referring to flammable, brown or black mixtures of tarlike hydrocarbons, derived naturally or by distillation from petroleum. . A
graphic example of a homogenizing processing promoter at work can be
seen in the electron microscope electron microscope: see microscope. pictures of an NR/SBR/BR blend with and
without the homogenizing agent Rhenosin TP 100 in figure 4. The large
color variation in the first picture indicates areas of unmixed polymer
phases, while the uniform color in Verb 1. color in - add color to; "The child colored the drawings"; "Fall colored the trees"; "colorize black and white film"color, colorise, colorize, colour in, colourise, colourize, colour the second picture indicates good homogeneity of the mix. [ILLUSTRATION OMITTED] Misconception mis·con·cep·tion n. A mistaken thought, idea, or notion; a misunderstanding: had many misconceptions about the new tax program. Some people believe that a simple process oil can be used as a process promoter. This is a misconception. The data in table 9 distinguish rather dramatically the differences between a processing promoter and a process oil. Process promoters do function as plasticizers plasticizers mostly triaryl phosphates, such as tricresyl, triphenyl phosphates, which are poisonous. See also triorthocresyl phosphate. , whether you like it or not; however, they provide properties that a process oil cannot provide.
Table 9 - comparison between plasticizer and
process promoter
Compound 165.9 165.9
Naphthenic oil 13.0 10.0
Aktiplast T -- 3.0
178.9 178.9
Mooney ML (1+4) 100 [degrees] C 37 37
Mooney scorch 120 [degrees] C
t5-min. 40:39 39:22
t35-min. 45:05 43:23
Vulcanizate 150 [degrees]
C/20 min.
Hardness - durometer A 53 59
Modulus - MPa
100 1.5 1.9
300 6.0 9.0
500 11 16
Tensile - MPa 20 24
Elongation - % 830 690
Tear- N/mm 69 58
Compression set - %
168 h./70 [degrees] C 55 42
24 h./70 [degrees] C 34 25
24 h./RT 16 15
Hot air aging - 7d/70
[degrees] C
Hardness - ShA 57 +4 60+1
Modulus - MPa
100 1.8 + 20% 2.3 + 21%
300 12 + 53% 10 + 9%
500 22 + 73% 17 + 3%
Tensile - MPa 25 + 10% 23.5 - 2%
Elongation - % 580 - 37% 685 - 1%
Tear - N/mm 50 - 28% 57 - 3%
Rheovulcameter (100 [degrees]
C/150 [degrees] C mold)
Volume - ccm 1,930 2,165
Velocity (max.) - ccm/sec. 86 99
To demonstrate this phenomenon, we very conservatively used 13 parts of a naphthenic oil in the control stock and a comparison stock in which we replaced three parts of the oil with a zinc soap. As we look at the data, we see that the Mooney viscosity and Mooney scorch are the same, so you can say that the processing promoter behaved as a process oil. The rest of the data, especially the modulus See modulo. , as you may expect, is a lot higher because of the lower oil content. But due to the increased solubility of the zinc soap, some of this improvement is due to a much tighter rubber matrix. The tensile strength inevitably increases and percent elongation at break inevitably decreases due to better carbon black dispersion. The compression set values are much lower compared to the control stock. And last, but not least, if you look at the aging characteristics between the control stock and the one containing less oil and the processing aid, you see an astounding a·stound tr.v. a·stound·ed, a·stound·ing, a·stounds To astonish and bewilder. See Synonyms at surprise. [From Middle English astoned, past participle of astonen, difference. The compound with all oil ages poorly, which would indicate an obvious problem with the comly, which would indicate an obvious problem with the compound. Looking at a few specific properties Specific properties of a substance are derived from other intrinsic and extrinsic properties (or intensive and extensive properties) of that substance. For example, the density of steel (a specific and intrinsic property) can be derived from measurements of the mass of a steel bar , specifically the aging performance of the elongation, there is a difference of 37% for the oiled stock versus a 1% change for the stock mixed with the processing promoter. This is a significant difference. The differences in processability are nicely demonstrated in the injection molded volume. The stock with the processing promoter shows more than a 10% improvement over the other. Since this compound is a lot tougher, you would expect that it would be more difficult to process, but the reverse is true. Summary Processing promoters can provide dramatic improvements in mixing and processing of rubber compounds. The goal is to select the correct processing promoter to achieve the desired results, which is based on the properties to be changed and the base polymer of the compound. The four basic categories of processing promoters are peptizers or mastication aids, internal lubricants or dispersants, external lubricants and homogenizers. The solubility of the processing promoter in the base compound determines how it will function in that compound, either as a dispersant or lubricant. Processing promoters that are composed of several chemicals will perform the various functions to the extent of solubility and percent of each component in the base compound. Processing promoters should be added at the correct time in the mixing cycle to achieve maximum results. Peptizers are commonly added at the very beginning with the polymer. Dispersants are to be added with the fillers. Lubricants can be added even later in the mix cycle. Processing promoters can have an effect on Mooney scorch, t2 and t90; therefore, processing promoters should not be treated as simple additives to an existing compound, but rather, should be considered critical ingredients. |
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