EPDM Applications

China EPDM Market 2005 by Applications

8%
7%

11% 38%

extruded
13%
8% 15%

Auto Oil Add. Wire/Cable Building Tyre TPO/TPV Others

Colored Areas are mainly extruded materials

ca 60% of EPDM in China is extruded !
 Major EPDM Applications
Extruded profiles (automotive, construction, truck
container)
Wire and cable
Molded articls (washer / dryer door gasket, seals, spark
plug boot, muffler hanger, brake seals, o-ring)
Hose (radiator, heater, cooling, brake, firehose)
Conveyor belt
Sponges (profile, insulation)
Roofing membrane
Roller, roll cover
Plastic modification (TPO, TPV)
Oil viscosity adjustment
Tires (sidewall, tube)
Ethylene-Propylene Rubber

Extrusion and Continuous

Vulcanization
 Types of Extruded Profiles

Building Flocked
profiles glass run
Sponge tube channel

Door trims
wind shield seal
glazing profile
 Where to find extruded Profiles
Location of automotive
seals

Flame retardent
window profiles
for trains, Heurteaux
 Key Issues of Pressureless Vulcanisation

Continuous vulcanization (CV): fast growing curing

technique, requires
- capital investments
- restrictions in compounding must be observed

Shaping, curing & finishing in a single operation

above 200oC cure time for vulcanization can be in

the range of seconds

Tool Costs - low

Part costs - medium
Production rate - high
Multiple materials (dense & sponge) / durometers (soft & hard ) possible in the
same part
Compounding Extrusion Lines
post cure steps
Kneader
Coating, painting
2-roll mill
Adhesives, liner
Sheeting, strips
Flocking
Drying steps
cutting
From Tecrep
Curing
Shear head
HF-cure (often to get initial
stability) Cooling
Hot air tunnel, heat shock Spray
(Gerlach) Submersion
Glass beads air
Salt bath
How to Optimize a Sponge Rubber Formulation

size of cells
open or closed cell structure
surface appearance of the vulcanizate

Buna EP G 6950 100.0 phr

carbon black N 539 80.0 phr Variation of
Omya BSH (whiting) 40.0 phr
blowing agent,
paraffinic mineral oil 80.0 phr
PEG 4000 2.0 phr ZnO, kicker
Zinkoxyd aktiv 5.0 phr
sulfur 1.0 phr
Vulkacit Merkapto 2.0 phr Most important finding:
Vulkacit ZBEC 1.0 phr
Rhenocure ZADT 1.3 phr Cure Speed and Blowing
Vulkalent E 1.0 phr kinetics need to match
 Test Results
1265 A 14 14/01 14/02 cpd raw
Buna EP G 8850 100.0 - ML 1+4 100 (G 6850) : 38 MU 60
Buna EP G 6850 - 100.0 ML 1+4 100 (G 8850) : 40 MU 80
Ru N 539 80.0 80.0
ZnO aktiv 5.0 5.0
RPA Frequency experiment: compound loss angle tan
CaO 6.0 6.0
1.4
Kreide Omya BSH 40.0 40.0
Sunpar 2280 80.0 80.0 1.2

PEG 4000 2.0 2.0 tan d EPG 8850

1 tan d EPG 6850
Schwefel 1.0 1.0
Vulkacit Mercapto 1.0 1.0 0.8

tan
(MBT)
0.6
Vulkacit ZBEC 3.0 3.0 delta [0.01 Hz - 10 Hz]
EP G 8850: 0.385
Vulkalent E 2.3 2.3 0.4 EP G 6850: 0.656

Porofor ADC / M-C1 2.0 2.0

Porofor ADC / E 3.0 3.0
0.2
G 8850: higher melt elasticity
0
0.01 0.1 1 10 T = 100 100
Frequency [Hz]
 Extrusion Behavior & Mechanical Properties
EP G 8850/6850
Polymer EPG 8850 EPG 6850
Vulkanisation UHF / HL F (MPa) 11.7 11.3
Temperatures
D (%) 570 605
- before vacuum C 60
- after vakuum C 60 S 50 (MPa) 0.9 0.9
- screw C 30
S 100 (MPa) 1.5 1.5
- head C 80
- die C 90 S 200 (MPa) 3.4 3.1
- material @ die C 87
S 300 (MPa) 5.3 4.8
Pressures
- first stage bar 113 S 400 (MPa) 7.4 6.6
- before. vacuum bar 146
H (Stab) (Shore A) 50 50
-Die pressure bar 24
RPM rpm 8.6 Tear res. DIN 53515 N/mm 13.7 12.9
Power uptake kW 3.4
CS 22h/150C (%) 78 79
Torque Nm 1780 / 2200
Output rate (mass) kg/h 13.98 / 14.76
Total energy per kg kWh/ kg 0.243
Extrudate appearance (optical) very smooth/smooth
Conveyor speed m/min 4
UHF power % 35
Temperature hot-air device C 260
Vulcanisate sponge density g/cm 0.341/ 0.445
 Curing & Expansion Behavior
2 kinds of
blowing
agent to get
large and
small
1. Deviation
bubbles
EPG
Integral
EPG
8850 EP G
6850 6850
Same Expansion, same cure (not shown here)

Smoother
surface,
lower
density
17.2 : 1
17.2 : 1 2000 m
2000 m
 Formulation Examples
Sponge Profiles, Buna EP G 8850
Mooney 80, ENB 8, Ethylene 51, oil 0, long chain branching - high
Formulation
phr
Buna EP G 8850 100 Properties
Carbon Black, N550 90
Mistron vapor RE 40 Compound Mooney 49
Sunpar 2280 70 ML (1+4) @ 121C
ZinkOxyd aktiv 4 Mooney Scorch
Stearic Acid 1 T05 @ 121C, min 6.7
Agerite statalite S 1
Desical P 8 Density, g/ml 0.1.7
Sulfur 1.5
Compression 5.7
Vulkacit Merkapto (MBT) 1.5
Vulkacit Thiuram/C (TMTD) 0.8 Deflection, (50%), N
Rhenogran DPTT-70 1.95 Tensile, MPa 0.7
Porofor ADC/MC-1 2 Elongation, % 139
Porofor ADC/E-C 4

Total 326.05
 Automotive Body Sealing
Glass run channel
Door & trunk seal Window seal, Encapsulation
sponge or sponge+dense Sunroof seal
dense

a E PG
B u n 50
88 Buna EP T/G 6470
z Improved processing Buna EP T 6861
Buna EP T 6650
Fast mixing Buna EP G 8460
Buna EP T 9650 Very good milling behavior
Good polymer and filler dispersion
Buna EP G 6850
Good extrusion behavior
z Fast cure, good physical prop.
z Good low temp. prop.
Dense Profile, 60 Shore A, Buna EP G 6850
Mooney 60, ENB 8, Ethylene 51, oil 0, long chain branching - low

Formulation Properties

phr Compound Mooney 39

Buna EP G 6850 100 ML (1+4) @ 100C
Carbon Black, N 550 150 Stress/Strain
Calcium carbonate 48 Cure 30' @ 160C
Sunpar 2280 107 Tensile, MPa 10.7
Desical P 8 Elongation, % 277
Carbowax 3350 1.5 100% Modulus 4.0
Stearic Acid 2 Shore A2 Hardness 60
Zinc Oxide 10 Stress/Strain, Aged 168h@ 100C
Sulfur 1.7 Tensile, MPa 11.2(+8%)
Vulkacit DM/C (MBTS) 1.4 Elongation, % 215(-22%)
Vulkacit Thiuram/C (TMTD) 0.35 Shore A2 Hardness 72(+5)
Vulkacit ZBEC 0.2 Compression Set, %
216h @ 70C 30
Total 430.15
 Flame Retardent EPDM Profiles
Prope rtie s of unc ure d c o mpound
cpd cpd Density 1.47 1.47
120 121 Batch temperature 94 99
ML1+4/100C 48 56
Buna EP G 2470 100 100
Prope rtie s of vulc anizate s
Zinkoxyd aktive 5 5 S te am c ure , 3 min/200C
Stearic acid 1 1 Tensile Strength (TS) 6.6 11.2
Elongation (EB) 290 270
Apyral B40E (4 m2) 170 -
Hardness (H) 84 88
Apyral B90E (9m2) - 170 Tear ASTM D 470 7 6
Ucarsil RC1; Union L.O.I. 29 27
Carbide 1,7 1,7 Hot Air Ag e ing (Chang e in % or S hore A)
7 d/135C
Vulkanox HS/LG
TS 1
(TMQ) 1 1
EB 4
Vulkanox MB2/MG 1 1 H 0
Disflamoll DPK - - s we ll in AS TM Oil 2 24 h/100C (Change s )
TS % +1
Sunpar 2280 - -
EB % -22
Rhenofit TRIM/S 1 1 H -33
Perkadox 14-40 5 5 V % 85
Total: 285,7 285,7
 Buna EP T 6861
Specially developed branching grade
E (wt%) 60
ENB (wt%) 8
Mooney ML(1+4)@125C 60 (85)
Oil (phr) 15
Application - Automotive body sealing
Extruded profiles - dense
Glass run channel
Flocked window channel
Gloss surface profile
Hard profile
Improved processing Very good milling behavior
Glossy surface Fast cure Excellent physical properties
 Highly Extended EPDM Compound
PROPERTIES
70 Duro Low-Cost Compound
phr
Compound Mooney
Buna EP T 5459CL 200.0
ML (1+4) @ 121C 67
(Ultra high raw polymer Mooney)
Carbon Black, N550 165.0
Stress/Strain
Carbon Black, N774 175.0
Cure 26 min @ 177C
Calcium Carbonate 100.0
Tensile, MPa 5.5
Hard Clay 100.0
Elongation, % 210
Paraffinic process oil 115.0
100% Modulus 2.8
Calcium Oxide 7.0
Shore A2 Hardness 72
Polyethylene Glycol 3.0
Zinc oxide 5.0
Stress/Strain, Aged 168h @ 70C
Stearic acid 1.0
Tensile, MPa 5.8(+7%)
Sulfur 1.5
Elongation, % 205(-4%)
MBTS 1.5
Shore A2 Hardness 75(+3)
TMTD 0.8
ZBEC 0.8
Compression Set, %
216h @ 70C 30
Total 875.6
Wire & Cable
Buna EP Formulation
G 2470LM G 2470LM
EPDM 100
G 3963 Clay 60
T 5459 Silane 1
G/T 6470 Red Lead 5
T2450 TMQ 1.5
PE Wax 5
Paraffin Wax 5
Cable insulation ZnO 5
Low cost insulation Dicup 40% 6.5
Filling compounds
Sheaths & jackets Total (phr) 189
Cups and sockets
 Buna EP G 2470LM
Specially developed for Cable Application

E (wt%) 70
ENB (wt%) 4.2
Mooney (ML1+4 at 125C) 22

Easy processing and extrusion

Excellent insulation stability in water

Major applications:
Power cable and medium voltage insulation
Low voltage insulation
Cable jacket , Connectors, Cable fillers
 Other Buna EP Grades in Cable

Texas Grades (T 2450, T 2460, T 6470) in low voltage applications

Marl Grades (G 5450, G 6470) in low to medium voltage applications

Buna EP T 5459 CL in electrical connectors, cable fillers

Automotive and Industrial Hose
Formulation
(phr)
Buna EP G/T 6470 100
Carbon Black, N550 70
Carbon Black, N774 25
SatintoneSP-33, Kaolin 85
Sunpar 2280 70
Zinc Oxide 3
Stearic Acid 1
Carbwax 3350 3
Vulkanox HS/LG 1.5
Vulkanox MB-2/MGC 1
Sulfur 0.5
Sulfasan DTDM 1.5
Vulkacit DM (MBTS) 1.5
Vulkacit L (C) (ZDMC) 0.8
Vulkacit LDB/C 1.5
Vulkacit Thiuram (TMTD) 0.8
Coolant Hose Vulkalent E 1
Total 367.1
Compounding EPDM to reduce oil swell
 EPDM
Compounding to improve oil resistance
EPDM is not considered an oil resistance rubber but
improved oil resistance can be done by using compounding
techniques
Many applications require improved oil resistance
Air duct , gaskets, O-rings etc.
General compounding approaches:
Use ultra high MW grades (Mooney > 250, oil extended
grades)
Use modified EPDM grades (grafting) cost
Blend with NBR compatibility and issue
High filler / oil loading
Use high ethylene EPDM grades
Tight crosslinking
 Buna EP T 4969 based compound with
Improved oil resistance
BUNA EP T 4969 200 Chg. Ulti. Tens. (%) -70
CARBON BLACK, N 660 185 Chg. Ulti. Elong. (%) -40
CARBON BLACK, N 990 50 Wt. Change (%) 46.9
STEARIC ACID 1 Vol. Change (%) 60.8
SUNPAR 2280 30
ZINC OXIDE 10 ASTM FUEL C AGING: 70 HOURS AT 23C
BUTYL TUADS (TBuTD) 4 Hardness Shore A2 (pts.) 53
SPIDER SULFUR 2 Ultimate Tensile (MPa) 4.35
CBS 2 Ultimate Elongation (%) 75
Total 484

ASTM FUEL C AGING: 70 HOURS AT 23C

STRESS STRAIN
Hardness Shore A2 (pts.) 53
Hardness Shore A2 (pts.) 65
Ultimate Tensile (MPa) 4.35
Ultimate Tensile (MPa) 9.16
Ultimate Elongation (%) 75
Ultimate Elongation (%) 108
Chg. Hard. Shore A2 (pts.) -12
Stress @ 100 (MPa) 8.1
Chg. Ulti. Tens. (%) -53
DIE C Tear (kN/m) 10.9
Chg. Ulti. Elong. (%) -31
Wt. Change (%) 36.6
Vol. Change (%) 59.5

Buna EP Grades recommended : T4969, T5459CL, T6465, T9650

G5567, G3459
 Buna EP T 4969
Ultra High MW Oil extended Grade

E (wt%) 62
ENB (wt%) 9.8
Mooney (ML1+8 at 150C) 30
Oil (phr) 100

Major Applications

Extruded products, Molded articles,

Sponge products
Develop Low Hardness EPDM Compounds
(< 40 Shore A)
 Develop Low Hardness EPDM Compounds
(< 40 Shore A)
Challenge
Low compound viscosity (poor mixing and curing process)
Low tensile due to high oil / low filler loading

General technical approaches

Use high mooney grades (>70)
Choose either high ethylene or low ethylene grade depend on
compounding approaches
Use high MW oil extended grades are recommended
Sulfur sure system is suggested
Challenge to develop high tensile (>14 MPa). Need special filler
selections
 40 Shore A Compound
BUNA EP T 4969 200 Other Buna EP Grades
N 550 BLACK 100
N 770 BLACK 30 recommended in this
Whiting
SUNPAR 2280
30
65
application
STEARIC ACID 1
ZINC OXIDE 5 Buna EP T 5459CL
PEG3350 1
SPIDER SULFUR 0.7 Buna EP T 6565
MBTS 1
ZDBC 1.5
TMTD 0.5
Buna EP T 6470
DPTT 0.4
Buna EP T 9650
Total 436.1
Buna EP G 5567
Hardness Shore A 40
Tensile (MPa) 11.9 Buna EP G 3569
Elongation (% ) 600

Compound Mooney (ML1+4 at 100C) 36

 Fire Hose
Buna EP T 6470 or Buna EP G 6470

High ethylene content and medium cure rate

Easy mixing low density bales
High green strength
Easy extrusion
Excellent physical properties
Mooney at 125C ENB% Ethylene content %

Buna EP T 6470 57 4.5 68

Buna EP G 6470 59 4.7 70

EPDM in Tire Applications

Tire Sidewall
Innertube
Bicycle Tire
EPDM Molecular Structure

Number of double bonds:

3 .. 15 / 1000 C-Atoms, or
0 .. 11 wt% diene monomer (ENB)

Reference data:
NR: 200 / 1000 C
SBR: 80 / 1000 C
Buna EP grades in tire sidewall and bicycle tread /sidewall
 PASSENGER TIRE
Tread
Buna SL (SSBR)
Buna VSL (VSSBR)
TAKTENE (Co BR)
Buna CB (Nd BR)
Carcass Ply Skim Base
TAKTENE (Co BR) TAKTENE (Co BR)
Buna CB (Nd BR) Buna CB (Nd BR)
Innerliner
Lanxess Bromobutyl Sidewall
Lanxess Chlorobutyl Buna EP (EPDM)
TAKTENE (Co BR)
White Sidewall Buna CB (Nd BR)
Buna EP T (EPDM)
TAKTENE (Co BR)
Buna CB (Nd BR)
lanxessChlorobutyl
Rubber Chemicals Apex
Vulkacit (Accelerators) TAKTENE (Co BR)
Vulkanox (AOs) Buna CB (Nd BR)
Vulkalent (Retarder) Buna CB (Li BR)
Renacit (Peptizers)
Cohedur (Bonding Agents)
Rimstrip
TAKTENE (Co BR)
Buna CB (Nd BR)
 Buna EP Grades in Tire Sidewall

Buna EP Buna EP Buna EP Buna EP

T3950 T6650 G6850 T4969
Mooney at 33 62 60 43
125C
ENB % 11 6.5 8 9.8

Ethylene % 56 53 51 62

Oil content 100

phr
Buna EP in Tire Sidewall
NR (SMR) 50 60
High cis BR 50 -
Buna EP T 4969 - 80
N660 black 50 50
Naphthenic oil 10 7
TMQ (Vulkanox HS) 2 1.5
6 PPD (Vulkanox 4020) 2 -
Wax 2 -
Zinc Oxide 3 3
stearic acid 2 2
sulfur 1.75 1.75
MBS (Vulkacit MOZ) 1 -
CBS (Vulkacit CZ) - 1
 Buna EP in Tire Sidewall

EPDM can be used to blend with NR, NR/BR or

NR/SBR blend to improve ozone and antiflex
cracking properties
The optimum level of EPDM is 20 to 40%
EPDM grades with high ENB content is
recommended to provide necessary co-cure rate
with NR, BR and SBR.
 Buna EP T 6250 in innertube compound

Raw Polymer Properties (Typical):

Mooney Viscosity at 125 C: 55
% Ethylene (corrected): 62
% ENB: 2.3
Specific Gravity: 0.86
Buna EP T 6250 in a Butyl Innertube Compound

Test Recipe:
Lanxess Butyl 301 100-80
Buna EP T 6250 0-20
N660 Black 65 (+5,+10)
Paraffinic Oil 22 (+2,+4)
Stearic Acid 1.0
Zinc Oxide 5.0
Sulfur 1.8
MBT 0.5
TMTD 1.0
Permeability to air
 EPDM in butyl tube compounds

Buna EP T 6250 can improve green strength and

tack of butyl innertube compounds.
The blend will help to prevent innertube failure in
severe service by balancing crosslinking and chain
scission.
The blend produces very minimal increases in air
permeability, which can be reduced via filler
increases.
Lower compound cost
Buna EP in other applications
 Disc Brake System Formulation
Brake cups, brake diaphragm (phr)
Buna EP G 3440 100
Carbon Black, N539 50
Oppanol B3 15
Zinc Oxide 5.0
Carbowaxs 3350 3
Vulkanox HS (TMQ) 1
Sartomer SR 350 1
Perkadox 14/40 5
Total 180

Mooney% ENB% Ethylene%

Buna EP G 3440 28 4 48
Buna EP T 2450 22 4 59
 Golf Club Grip
Formulation #1 #2
Buna EP T 4969 200 200
Carbon Black, N 550 5 100
Silica 55 15
Silane 1 1
Paraffinic Oil (Regular or Clear) 0 50
Zinc Oxide 5 5
Stearic Acid 1 1
Polyethylene glycol 0 2
Tackifier 1 1
Sulfur 0.7 1
MBT 2 1.5
TMTD 0.7 0.7
DTDM 1.5 0
DPTT 0.5 0.8
TDEC 0 0.7
Total (phr) 273.4 379.7

Other Grades: Buna EP T 2460, T6650, T6470, T6465.

Buna EP G 8460
 Technical Articles
Door
Gasket
Washing
Machine
Gasket

Buna EP G 5567
Molded Seals
Buna EP T 6465 (phr)
Valve Buna EP T 9650 100.0
Buna EP T 9650 ZnO 5.0
Gasket
Stearic acid 0.5
N 550 black 100.0
N 762 black 50.0
Sunpar 2280 110.0
Vulkacit Thiuram (TMTD) 0.6
Conveyer Belts Vulkacit LDB (ZDBC) 2.0
Flooring DPTT 1.5
Tank lining Rhenocure (DTDM) 2.0
Total 371.6
Bellows and Bumpers
Building & Construction
Formulation
(phr)

Buna EP T 6250 100.0
Sunpar 2280 95.0
N 650 black 140.0
Zinc oxide 5.0
Stearic acid 1.0
Sulfur 0.8
Vulkacit Thiuram (TMTD) 0.5
TETD 0.5
Vulkacit NZ (TBBS) 2.5
Total 345.3

Roofing
membrane
Building
profiles
Rubber Rollers and Roll Cover
Formulation (40 Shore A)
(phr)
Buna EP T 5459 CL 200
(Clear oil extended)
Silica 40
Talc 25
Hard Clay 50
Clear Paraffinic Oil 25
Zinc Oxide 5
Stearic Acid 1
Polyethylene glycol 2
Sulfur 1.5
ZDBC 0.8
MBT 1.2
TMTD 0.8
Total (phr) 352.3
 EPDM in Belts
V-belt, poly-V belt, micro-V, power transmission belt, industry belt

CR is being replaced by EPDM

Depend on each companys formulation and belt
design. EPDM requirements is different.
Gates-Unttia in Asia uses mainly Keltan740
Buna EP T 6250 or G6170 is recommended.
 EPDM in sports field

Sports field (playground, artificial grass,

running track)
Use low cost grades and off-spec

CODE CODE
GRANULES NUMBER COLOUR GRANULES NUMBER COLOUR
80 Red 93 Beige
81 Green 94 Eggshell
82 Grey 95 White
83 Yellow 96 Bright Red
85 Blue 97 Lime Green
88 Earth Yellow 98 Cream
89 Brown 99 Special Blue
90 Green 100 Teal
91 Apple Green 102 Rainbow
g
92 Purple 104 Orange
 EPDM in Condenser Cap
Capacitor construction :

Collection of Condensers
Thank you very much
for your Attention