1 Cancarb July 3, 2019

Overview

• Thermax® Thermal Carbon Black

• Thermax® vs. Furnace Black
• The Thermax Advantage
• Natural Rubber
• Nitrile Rubbers
• Hydrogenated Nitrile
• Polychloroprene
• Fluoroelastomers
• NBR/PVC Blends
• Ethylene Propylene Rubbers
• Chlorosulfonated Polyethylene Rubbers – CSM
• Butyl and Halobutyl Rubbers
• Questions & Answers

2 Cancarb July 3, 2019

Thermax®

• Carbon black can be broadly defined as very fine particle

aggregates of carbon, possessing an amorphous quasi-
graphitic molecular structure

• The most significant areas of distinction between thermal

black and furnace black are particle size and structure

• Thermax®, thermal carbon black, due to its higher particle

size (280 nm) and lower structure, compared to even the
most coarse furnace black, can be translated into excellent
rubber compound properties

3 Cancarb July 3, 2019

Thermax® vs. Furnace Black Grades

Particle Size Diameter

N762 N990
(80nm) (280nm)

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Thermax® vs. Furnace Black Grades

Low Structure Moderate Structure High Structure

N990 N762 N550

5 Cancarb July 3, 2019

The Carbon Black Spectrum

140

N343 N121
N650
OAN (DBP) ABSORPTION (ml/100g)

120 N550 N339

INCREASING STRUCTURE

N539 N220 N110

100 N330
N660
80
N774 N326
N762
60

40
N990

20

0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
NITROGEN SURFACE AREA (m2/g)

DECREASING PARTICLE SIZE

6 Cancarb July 3, 2019

Influence of Carbon Black on
Properties

As Particle size As Structure

Rubber Property
Increases Decreases

Mixing temp.

Dispersion

Viscosity

Green Strength

Extrusion Quality

Scorch Safety

7 Cancarb July 3, 2019

Influence of Carbon Black on
Properties

As Particle size As Structure

Rubber Property
Increases Decreases
Tensile

Elongation
Hardness

Tear resistance

Compression set

Heat build up
Abrasion resistance

Resilience

8 Cancarb July 3, 2019

The Thermax® Advantage

The properties of Thermax® can be translated into rubber

compounds with:
• Lower heat build-up, especially during extrusion, which is very
important for halogen bearing rubbers and high hardness
compounds

• Low hysteresis loss in dynamic applications, for example;

automotive engine mounts

• Reduced volume swell in aggressive fluids

• Reduced cost

• Low compound viscosity which is essential for injection molded

and sponge compounds

9 Cancarb July 3, 2019

Natural Rubber (NR)

Natural Rubber Structure

CH3 • Natural rubber is polyisoprene

– CH2 – C = CH – CH2 – • There are four possible isomers of

natural rubber

cis–1,4 Isomer
• 1,4 structure means that ‘C’ atoms 1
-CH2 CH2- and 4 are joined in forming the chain
C=C
• In the cis-1,4 structure both carbon
CH3 H atoms 1,4 forming the chain are on
the same side of the double bond

10 Cancarb July 3, 2019

Natural Rubber (NR)

• Natural Rubber has outstanding mechanical properties and

fatigue resistance making it a very popular choice in
dynamic applications

• Natural rubber consists of polymer chains all having almost

100% perfect cis–1,4 structure. The true chemical name
for this polymer is in fact, cis-1,4-polyisoprene

• When the units in a macromolecule all consist of the same

molecule, the polymer is said to be stereo regular

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Properties of Natural Rubber (NR)

Natural Rubber:
• Crystallizes on stretching, resulting in:
• high gum tensile strength
• high tensile strength/elongation @ break
• very high tear strength & hot tear resistance
• excellent De Mattia cut growth resistance
• Gives a glass transition temp (Tg) of approximately -75°C
• Has high resilience
• Has excellent tack & green strength properties
• Imparts low damping (hysteresis) and low heat build-up in
dynamic deformation
• Is unsaturated (double bonds), resulting in poor resistance
to:
• Heat aging
• Ozone
• Oils and hydrocarbons
12 Cancarb July 3, 2019
Applications of Natural Rubber

Common Applications of Natural Rubber are:

• Truck tire tread (Tear, hot tear, low heat build-up)

• Passenger radial (Flexibility, low heat build-up)

• Anti-vibration (Dynamic deformation)

• Conveyor belting (High mechanical properties, tear)

• Adhesive tapes and solutions (Tack)

13 Cancarb July 3, 2019

The Thermax® Advantage in Natural
Rubber Compounds

• Thermax® maintains the inherent good dynamic

properties of the natural rubber polymer
• The best choice for anti-vibration applications

• Thermax® lowers compound hardness while retaining the

good tack properties inherent to natural rubber
• Excellent for cushion gum compounds

• In wiper blade applications, higher loadings of Thermax®

lower the rubber content of the compound which is
essential for low noise and a good surface finish.

14 Cancarb July 3, 2019

NR Compound Example Using
Thermax®

Natural Rubber Engine Mount

SMR 100 100

Zinc Oxide 3 3
Stearic acid 1 1
A.O. TMQ 1.5 1.5
N 762 15 15
Thermax N990 45 70
Aromatic Oil 15 15
CBS 3 3
TMTD 0.5 0.5
Sulfur 0.5 0.5
Cure time @ 160°C 11‘ 11‘
Hardness 43 49
Tensile strength 206 178
Elongation @ Break % 535 480
Dynamic testing at 20 Hz
Tan Delta at 25°C 0.084 0.027

15 Cancarb July 3, 2019

Nitrile Rubber (NBR)

Nitrile Structure

butadiene acrylonitrile

-
- CH2 - CH = CH - CH2 + - CH2 - CH -

CN

Polymer Unit

- (CH2 - CH = CH - CH2)n - CH2 - CH -

( )
CN m

16 Cancarb July 3, 2019

Nitrile Rubber (NBR)

• Nitrile rubbers are high molecular weight copolymers of

1,3-butadiene and acrylonitrile

• The percentage of acrylonitrile content can be varied

from 18% to 50%, and will influence the performance
characteristics of the polymer

• The great variation in acrylonitrile content possible with

nitrile rubber, allows for compounds to be customized to
highlight specific required properties

17 Cancarb July 3, 2019

Nitrile Rubber – Effect of Acrylonitrile
Content

Increases

Density

Processability

Cure rate – Sulphur Cure System

Oil/fuel resistance

Compatibility with polar polymers

Thermoplasticity
Stiffness

Tensile

Abrasion resistance
As ACN Increases
Heat – aging resistance

Decreases
Resilience

Cure rate – peroxide system

Low temperature flexibility

Air/gas permeability

18 Cancarb July 3, 2019

Nitrile Rubber – Effect of Mooney

Increases

Acceptance of fillers/plasticizers

Incorporation time of fillers

Mixing temp
Sheet formation time on mill

Mill shrinkage

Green strength

Modulus

As Mooney Increases

Decreases

Porosity

Compression set

19 Cancarb July 3, 2019

Properties of Nitrile Rubbers

Nitrile Rubber:

• Has very good oil and fuel resistance

• Can perform over a wide temperature range

• Has inherently good resistance to gas permeation which

increases as the level of acrylonitrile increases

• Can be blended, up to 50%, with polyvinyl chloride (PVC) to

produce compounds that exhibit good weathering
characteristics in addition to good dynamic properties

• Can be co-polymerized with methacrylic or acrylic acid to

produce carboxylated nitrile (XNBR), which is noted for its
excellent dynamic properties and abrasion resistance

20 Cancarb July 3, 2019

Applications of Nitrile (NBR)

Common Applications of Nitrile Rubber are:

• Gaskets and seals – NBR, XNBR (for high hardness)

• Hoses – NBR (mainly in tubes), NBR/PVC (mainly in covers)

• Belting – NBR

• Rollers – NBR, XNBR (for high hardness)

• Cable Jackets – NBR/PVC

• Textile (spinning cots/aprons) – NBR, NBR/PVC, XNBR

• Industrial footwear – NBR, NBR/XNBR blend, NBR/PVC sponge

• Insulation – NBR/PVC sponge

• Molded/extruded components for various industries & automotive

• Fabric proofing – NBR

• Milking inflation - NBR

21 Cancarb July 3, 2019

The Thermax® Advantage in NBR
Compound Applications

• Higher loadings are achievable with Thermax®, which

reduces the rubber content enabling for lower swell in
aggressive fluids
• Gaskets and seals

• Thermax® promotes good extrusion properties and low

heat development, avoiding potential scorch problems.
This is critical for high hardness compounds
• Hydraulic hose tubing

• Thermax® maintains the desired hardness of a compound

while lowering the viscosity for effective blowing
• NBR/PVC Sponge Insulation, hoses and soles

22 Cancarb July 3, 2019

Nitrile Compound Example Using
Thermax®
Hydraulic Hose (Broad Temperature Range)
Nitrile Rubber 100 (33-34% ACN, 75-80 Mooney)
ZnO 5
St. acid 1
Processing Additive 2
A.O. Aminox 2 (DPA + Acetone reaction product)
A.O. ZMBI 2 (Zn Salt of 2 – Mercaptobenzimidazole)
N550
N990
50
50 > Suitable blend for good processing,
vulcanizate properties and good heat
ageing
10 >
Blend of polyester and phosphate
Paraplex G-25
plasticizers for resistance to heat extraction
KP 140 10
and low temperature cracking
Sulfasan R 1
CBS 3
TMTD 3
Cure @ 166° 15'
SH / TS / EB 70 / 152 / 270
Vol. swell % 19 (ASTM Oil 3 / 70h 135°C)

Blending with Thermax N990 helps improve scorch safety during extrusion due
to lower heat development. Higher filler loading improves over all extrusion
properties and sealing with end couplings
23 Cancarb July 3, 2019
Hydrogenated NBR (HNBR)

Hydrogenated nitrile rubber is based on NBR that has been

chemically altered (hydrogenated), resulting in a much lower
amount of unsaturation in the polymer backbone. HNBR
exhibits significantly improved heat resistance, compared to
NBR, while retaining excellent oil and fuel resistance.

HNBR Range

% Hydrogenation % ACN content Mooney (ML 1+4 @ 100°C)

~ 85 to 99+ 17 to 50 50 to 150

24 Cancarb July 3, 2019

Comparison with NBR for 50 phr FEF
compound-Peroxide cured

HNBR+ 50 phr FEF NBR+ 50 phr FEF

99+ % hydrogenation
38% ACN 38% ACN
55* Mooney 50** Mooney
Mooney (ML 1+4 @ 100°C) 43 86
Hardness (Shore A) 68 76
T.S. (M.Pa) 17.5 21.9
EB (%) 390 180
Tear Die C (KN/m) 15 16.7
Comp. Set % (168h/150°C) 18 27
Abrasion (DIN mm3 loss) 145 260
Air Ageing (168h/150°C)
Hardness +8 +17
T.S. (%) Nil Brittle
EB (%) -30 Brittle

The significant improvements in the properties of HNBR over NBR, especially in

compression set & heat ageing, bring HNBR very close to specialty rubbers.
*ML 1+4@125oC
**ML 1+4@100oC

25 Cancarb July 3, 2019

Hydrogenated NBR (HNBR)

HNBR* ACM FKM VMQ

Tensile 1 3 3 7

Heat Resistance 3 3 1 1

Comp. Set 2 2 1 1

Low Temp 3 5 7 1

Gear Oil 1 1 4 7

ASTM Oil #1 1 3 4 7

Sour Gasoline 2 5 1 7

Rating:1 Best; 7 Worst

*99+ % Hydrogenation
26 Cancarb July 3, 2019
Applications of HNBR

• Timing belts (automotive) – ozone resistance, flexing

• Power steering rotary shaft seals

• ‘O’ rings

• Oil well specialties

• Rollers

• Air conditioning hoses for cars

27 Cancarb July 3, 2019

The Thermax® Advantage in HNBR
Compounds Applications

• HNBR rubbers have inherently good mechanical properties and

do not require a reinforcing black. Thermax® maintains the good
mechanical properties of HNBR while lowering the compound
viscosity which is essential for easy processing

• Thermax® does not degrade the excellent compression set of the

HNBR polymer

• Higher loadings are possible with Thermax® resulting in lower

polymer content which provides lower oil swell and a significant
reduction in the overall compound cost

• Thermax® allows for extrusion with lower heat build-up giving

better scorch safety and further improved impermeability of
HNBR

28 Cancarb July 3, 2019

HNBRLow
Compound Example
Compression SetUsing
HNBR Seal
Thermax®
Low Compression Set Seal
TORNAC A 38.55 (99.5% saturation) 100
Thermax® N990 50
Plasticizer WB 300* 5
ZnO 5
Stearic acid 1
Trigonox 101-45** 8
TAIC 3
ML 1+4 @ 100°C 70
MS Mooney Scorch at 125°C >25 ‘
Cure time at 180°C 9’
SH/TS/EB 60/146/235
Air aging 150°C / 168H +8/-3/-40%
Compression Set 70 h / 150°C 12

Thermax® maintains good low compression viscosity/mold flow, allows for

less polymer content, low swell, adequate tensile strength and excellent
compression set
*Mixture of Aliphatic / Aromatic polyesters
** 2,5 dimethyl – 2,5 bis (tert butyl peroxy) hexane (Akzo).

29 Cancarb July 3, 2019

NBR/PVC Blends

• Both NBR and PVC are polar which makes them very
compatible, typically a 70/30 ratio

• NBR provides resistance to heat and organic fluids but has

poor resistance to weathering and ozone due to
unsaturation.

• PVC provides resistance to weathering, ozone and aliphatic

hydrocarbons oils

• PVC also improves processing, reduced flammability and

mechanical properties such as T.S., tears and abrasions

30 Cancarb July 3, 2019

Carboxylated NBR (XNBR)

• Carboxylated NBR (XNBR) is a terpolymer NBR with acidic

organic monomer (typically 1 & 7%) carboxylic acid as a
third monomer

• Reactions of ZnO and Carboxylic Acid result in a matrix with

significantly increased mechanical properties, such as higher
hardness, abrasion resistance and tear strength

• Although sacrifice in processing (mill and mould sticking)

scorch, resilience and low temperature resistance, product
retains the basic properties of NBR (oil & fuel resistance)

31 Cancarb July 3, 2019

Applications

• Gasket and Seals - mainly NBR, high hardness seals ex/

Mud Pump – XNBR
• Hoses – NBR mainly in tubes, NBR/PVC bend mainly in
cover
• Beltings
• Rollers – NBR, XNBR for higher hardness rollers
• Cable Jackets – NBR/PVC blends
• Textile – spinning cots/aprons, NBR, NBR/PVC, XNBR
• Industrial Footwear – NBR, NBR/XNBR blend, NBR/PVC
sponge soiling
• Insulation – NBR/PVC sponge
• Moulded/extruded components for various industries,
automotive
• Fabric proofing – protective coatings, NBR
• Milking inflation – NBR, resistance to fat
32 Cancarb July 3, 2019
NBR/PVC Blend Example Using
Thermax®
Gasohol Resistant Hoses Compound 1 Compound 2
NBR/PVC Blend70/30 100 100
Sulphur 1.5 1.5
ZnO 5 5
St. acid 1.5 1.5
N550 25 30
Thermax® N990 45 60
DOP 23 30
A.O. ODPA 1.5 1.5
P. Wax 3 3
TMTM .5 .5
ML, 1+4@ 100°C 34 34
MS, t5 @125°C 23’ 22’
Cure Time @ 160°C 7.5’ 7.5’
SH/TS/EB 68/143/450 70/131/415
Comp. set 22 h/70°C 27 27
Ageing in M15 test fuel (FAM 85 – Methanol 15), 48h at 23°C
Change -18/-59/-60/+47.8v -19/-27/-51/+39v
High loading of Thermax® lowers the polymer content allowing for low
swell in aggressive fuels, low compression set and good extrusion.

33 Cancarb July 3, 2019

Polychloroprene (CR)

Polychloroprene Structure

2-chlorobutadiene trans-1,4 polychloroprene (88-92 %)

-CH2 H
CH2 = C – CH = CH2
C=C
Cl
Cl CH2-

Chloroprene (liquid) Similar to trans-1,4 isoprene but, the

‘CH3’ group has been replaced by ‘Cl’

34 Cancarb July 3, 2019

Polychloroprene (CR)

• Polychloroprene is often called neoprene. Neoprene is, in

fact, the trade name of Dupont Dow Elastomers
polychloroprene product line

• Polychloroprene has a structure similar to that of natural

rubber except one of the methyl side groups is replaced by
a chlorine atom and it is a trans-oriented molecule

• Polychloroprene can be sulfur modified or mercaptan

modified to provide specific desired properties

35 Cancarb July 3, 2019

Properties of Polychloroprene (CR)

Polychloroprene Rubber:

Crystallizes on stretching, allowing for:

• High gum tensile strength; similar to Natural Rubber (NR)
• Very good fatigue resistance

• When sulfur modified, will provide:

• Excellent fatigue resistance
• Highly resilient compounds
• High tear resistance

• When mercaptan modified, will provide:

• Better raw polymer stability
• Good resistance to heat
• Good resistance to compression set

36 Cancarb July 3, 2019

Applications of Polychloroprene

Common applications of polychloroprene rubber are:

• Adhesives – polarity-bonding

• V-belts – tack and fire resistance

• Timing belts – tack and fire resistance

• Bellows – high flexibility

• Automotive seals

• Bridge bearing pads – good dynamic properties and ozone

resistance

• Wire and cable – resistance to abrasion, oil, flame and weathering

resistance

• Hose (especially covers) – good weathering resistance

37 Cancarb July 3, 2019

The Thermax® Advantage in
Polychloroprene Rubber Compounds

• Thermax® will not degrade the inherently good

mechanical properties of polychloroprene

• Thermax® lowers the compound viscosity which is

essential for lower heat build-up during extrusion and
good mold flow

• Thermax® will maintain the good compression set of the

polychloroprene rubber

• Higher loading of Thermax® is possible resulting in a

lower rubber content which decreases oil swell and
reduces the compound cost

38 Cancarb July 3, 2019

Polychloroprene Compound Example
Using Thermax®

Wiper Blade Compound

Neoprene WRT 60
SMR CV 60 40
ZnO 5
MgO 4
Stearic acid 2
Thermax® N990 40
SRF 20
Paraffinic Oil 2-3
DPG 0.5
TMTD 0.5
Sulfur 1.0
6 PPD 1.5
TMQ 1.5
MC Wax 2
Hardness 60

High loading of Thermax® reduces the polymer content (cost savings) which
helps for low noise and gives a “clean” product & surface finish

39 Cancarb July 3, 2019

Fluoroelastomers (FKM)

Fluoroelastomer Structure

- (CF2-CH2)X - (CF-CF2)Y - (CF2-CF2)Z

CF3

VF2 HFP TFE

Vinylidine Hexafluoropropylene Tetrafluoroethylene
Fluoride

40 Cancarb July 3, 2019

Fluoroelastomers - FKM

• Fluorocarbon elastomers are a very popular choice for

difficult sealing applications

• Fluoroelastomers are created by substituting fluorine for

hydrogen on a carbon-based macromolecule

• Unlike hydrocarbon rubbers, which are non-polar, the

presence of fluorine creates polar molecules

• Fluoroelastomers are expensive and difficult to process due

to their relatively high molecular weight

41 Cancarb July 3, 2019

Properties of Fluoroelastomers

Fluoroelastomers:
• Can be compounded to provide high heat resistance and thermal
stability
• Have excellent oil & gasoline resistance
• Have excellent hydrocarbon-based solvent resistance
• Have very good impermeability
• Are flame resistant
• Are resistant to weathering
• Have excellent compression set resistance
• Are expensive
• Tend to have high Mooney viscosities which accelerate heat build-
up when mixing

42 Cancarb July 3, 2019

Applications of Fluoroelastomers

Common applications of Fluoroelastomers are:

• Automotive – Valve Stem Seals, Shaft Seals, ‘O’ Rings

• Aerospace – ‘O’ Rings for Hydraulic, Lubricating and Fuel Systems

• Oil Field – Packers & Blow-out Preventers

• Industrial – Expansion Joints in Mines, Gaskets, Valve & Pump

Linings

• Hoses – Fuel Lines, Turbo Chargers, Bio-diesel

43 Cancarb July 3, 2019

The Thermax® Advantage in FKM
Compound Applications

• High loadings of Thermax® will not reduce the excellent

compression set and low swell inherent to FKM
• Excellent for ‘O’ ring and seal applications

• The higher loading ability of Thermax® improves the

impermeability of the compound
• The best choice for fuel line hose veneer

• The specific gravity of Thermax® is similar to that of FKM, so

higher loading of Thermax allows for the same volume of
compound to be produced while using less of the expensive
FKM elastomer, without sacrificing the desired compound
properties.
• Overall compound cost reduction

44 Cancarb July 3, 2019

FKM Compound Example Using
Thermax®
FKM O-ring Compound 1 Compound 2
Dyneon FC 2176 100 100
Maglite D 3 3
Calcium Hydroxide 6 6
SRF 20 -
Thermax® N990 - 30
Press cure 10‘@177°C+Post cure 24hrs@260°C
Tensile Strength (psi) 2120 1970
Elongation at Break (%) 220 290
Shore A Hardness 80 76
Air Ageing 70 hrs/276°C
Tensile Strength (psi) 1695 1405
Elongation at Break (%) 330 295
Shore A Hardness 81 77
Compression set (%) 50 28
- Method B (0.139” O rings) 70 hrs/200°C

Thermax® enables higher loading while maintaining adequate original

mechanical properties with excellent ageing properties, compression set
resistance and low swell
45 Cancarb July 3, 2019
Ethylene Propylene Diene Rubber
(EPDM)

Structure
CH3
|
CH2 = CH2 + CH = CH2 + A Diene Monomer
Ethylene Propylene

Diene Monomers Used in EPDM

• DCPD - dicyclopentadiene
• ENB - ethylidene nobornene
• VNB - vinyl norbornene

Typically, ethylene comprises 45% to 80% of the polymer with the

diene making up 2.5% to 12%.

46 Cancarb July 3, 2019

Ethylene Propylene Diene Rubber
(EPDM)

Increasing the ethylene content in EPDM provides:

• Improved cold green strength
• Excellent theroplasticity which improves extrusion and mold
flow characteristics
• Increased filler and oil loading ability
• Higher heat resistance
• Good cured tensile strength properties
But:
• It is responsible for less building tack
• It is more difficult to mix
• Mill processing at low temperatures is difficult
• Compression set and recovery in cold temperatures is poor
• Flex resistance and elastic recovery are reduced

47 Cancarb July 3, 2019

EPDM – Molecular Weight
Distribution
EPDM Polymer can be produced with a range of Molecular Weight
Distribution (MWD).

High molecular weight distribution EPDM provides for:

• Excellent hot green strength, important for shaping and
continuous vulcanization
• High collapse resistance critical for hollow extruded sections
• Less porosity in extrudates
• Excellent physical properties
• Low compression set
• Improved resilience
• Facilitates oil and filler extension which improves the
difficult processing characteristics common to high MWD
polymers
• Higher loading of filler for lower cost compounds

48 Cancarb July 3, 2019

Ethylene Propylene Diene Rubber
(EPDM)

Increasing the diene content of the polymer provides:

• Shorter cure times

• Higher resilience
• Higher modulus
• Lower compression set
• Cure compatibility with unsaturated rubbers

49 Cancarb July 3, 2019

Properties of EPDM

EPDM based rubber offers:

• Excellent weather and ozone resistance
• Excellent high & low temperature resistance
• Excellent water and chemical resistance
• Excellent dielectric properties
But,
• Poor resistance to oils and hydrocarbon solvents
• Poor adhesion

50 Cancarb July 3, 2019

Applications of EPDM Rubber

Automotive industry
• Extruded Profiles – solid and sponge
• Hoses – Radiator and Heater
• Seals and grommets

Appliance Industry
• Washing machine parts – gaskets, elbows and hoses
Construction Industry
• Glass profiles
• Flooring
• Membranes
• Roofing

Electrical Industry
• Low and Medium voltage cabling – cable jackets
Chemical Industry
• Hoses
• Seals

51 Cancarb July 3, 2019

EPDM Compound Example Using
Thermax®
Automotive Moulded Sponge
Keltan 512 100
ZnO 5
St. Acid 1
Benzoic acid 1
Thermaxx® N990 100
Winnofil S (Coated pptd CaCO3) 35
Sunpar 150 60
Vaselin 10 Rotor/Roll Release
TMTD 2
MBTS 2
Sulphur 2
Benzene Sulphohydrazide 3
Benzene 1,3 Disulphohydrazide 3

ML 1+4@100°C 19
Cure time 15’@160
Specific Gravity 0.52

Higher Loading reduces costs. Low compound Mooney helps efficient

blowing, gives uniform cell structure

52 Cancarb July 3, 2019

Metallocene EPDM Technology

• The introduction of EPDM in the world market produced by

Metallocene Catalyst Technology has increased the scope for
the usage of Thermal Black in these rubbers considerably

• EPDM produced by Metallocene Catalyst Technology has very

high molecular weight compared to traditional EPDM Rubbers
produced from solution and suspension polymerization
technology

• EPMD Rubbers with Metallocene Technology are very difficult

to process when compounded with furnace blacks alone.
Blending Thermax in blend with the furnace black lowers the
compound viscosity allowing for easy processing without a
negative affect on mechanical properties

53 Cancarb July 3, 2019

The Thermax® Advantage in EPDM
Compound Applications

• High loadings of Thermax® can reduce the compound cost

without sacrificing compression set and dynamic properties

• Thermax reduces the compound viscosity which improves

processing, blowing and molding properties

• The very low grit level of Thermax maintains excellent

surface finish and ensures a uniform cell structure in sponge
applications.

• The excellent dispersion of Thermax results in consistent heat

transfer throughout the extrusion and uniform cooling

54 Cancarb July 3, 2019

Chlorosulfonated Polyethylene
Rubbers (CSM)
Structure

- (CH2-CH2)x – (CH2-CH)y – (CH2-CH)z -

| |
Cl SO2
|
Cl
Polyethylene, a low cost plastic, is chemically modified to a
cross-linkable rubber, retaining some of the important
properties of polyethylene such as chemical resistance and
electrical properties

This polymer is almost exclusively produced by DuPont

Performance Elastomers under the trade name Hypalon®. On
May 7th, 2009, DuPont announced that it will cease production
of Hypalon® and completely exit the CSM business

55 Cancarb July 3, 2019

Properties and Grades of CSM

Properties
• Excellent resistance to weather, ozone, sunlight, oxidation,
alkalies and acids
• Good resistance to oil and gasoline
• Good flame resistance, abrasion resistance
• It is close to polychloroprene in most properties but superior
in resistance to acids, alkalies, solvents, Ozone and oxidation
with better color stability

Grades
• Depending on the Cl content, range 24% to 43%, ‘S’ content
around 1%, varying Mooney
• Increasing Cl content give oil and flame resistance

56 Cancarb July 3, 2019

Applications of CSM Rubbers

Grade Cl content (%) Mooney Viscosity

ML 1=4 @ 100°C

Hypalon 40/40S 35 56/45

Hoses
W&C
Rolls
Hypalon 45 24 37
W&C
Low Temp. Applications
Hypalon 48/48S 43 78/62
Excellent oil resistance
low permeability to Freon
Air Conditioner Hoses

57 Cancarb July 3, 2019

Butyl Rubber (IIR)

Structure

CH3 CH3
| |
- CH2 – C -
|
+ - CH2 – C = CH - CH2 -

CH3
Isobutylene Isoprene

Butyl Rubber is a copolymer of isobutylene and a small amount of

Isoprene, typically around 2%

Chlorobutyl (CIIR) and bromobutyl (BIIR) rubbers are produced

in a similar manner, but with and additional halogenation stage
required

58 Cancarb July 3, 2019

Properties of Butyl Rubbers

• Presence of “bulky” isobutylene groups causes slow movement of the

polymer chain which gives butyl rubber excellent impermeability to air,
oxygen and water
• -CH3 groups along the chains interfere with each other, reduce the speed
with which the molecules

• Low unsaturation makes Butyl more resistant to heat ageing and to attacks
by acids, alkalis, oxidizing agents, ozone, water and steam, than general
purpose polymers such as SBR, BR and NR

• Butyl rubber is very similar in structure to polyisobutylene and has a similar

glass transition temperature (Tg) of -70°C

• Butyl has low resilience and very poor resistance to compression set, oil and
hydrocarbon based solvents

• Low unsaturation slows the compound cure rate and reduces Butyl’s
compatibility with the more unsaturated rubbers such as NR, SBR and BR.
Even small amount mixed in with these rubbers gives a disastrous effect on
compound properties

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Halobutyl Rubber

Isoprene Halobutyl
CH3 CH3 CH2
| Add X2 | + ||
- Minus H
-CH2-C=CH-CH2- (-CH2-C-CH-CH2-) + (X ) (-CH2-C-CH-CH2-) + (HX)
+
X=Cl or Br | |
X X

• Virtually all halogenation takes place at the isoprene portions of the IIR
Chains which represent approximately 2.0 mole% of the IIR Co-Polymer

• Commercial chlorobutyls contain 1.1 to 1.3% weight of chlorine and

bromobutyls contain 1.9 to 2.1% weight of Bromine

• Stearic hindrance of the double bond favors substitution rather than

addition, so most of the unsaturation is retained, although it is now
largely isomerised

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Butyl versus Halobutyl Rubber

Butyl rubber Chlorobutyl Bromobutyl

Cure reactivity
Compatibility with other unsaturated rubbers
Tack
Cure adhesion with other rubbers

• Increased cure compatibility reduces the need for stringent

precautions against contamination with other unsaturated
rubbers

• Flexibility and resistance to dry heat are almost identical for

both Chloro and Bromobutyl rubber

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Permeability of Halobutyl

Typical Tire Inner Liner Compound

Permeablility rates at 65°C Air Moisture

100% NR 8.3 13.3
100% SBR 6.8 11.0
HIIR/NR (60:40) 3.1 3.0
100% HIIR 1.0 1.0

The excellent permeability of Halobutyl rubber makes it a very

popular choice for tire inner liners

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Applications of Butyl and Halobutyl
Rubber

• Inner tubes for tires (IIR, HIIR)

• Heat resistant conveyor belts (HIIR)
• Tire Inner liners (HIIR)
• Tank linings (HIIR)
• Side Walls (HIIR)
• Dampers/bridge bearing pads (IIR/HIIR)
• Tire curing bladders (HIIR)
• Adhesives/sealants (cross-linked IIR, HIIR)
• Steam/Automotive Hoses (HIIR)
• Pharmaceutical closures (HIIR)

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The Thermax® Advantage in IIR &
HIIR Compound Applications

• High loadings of Thermax® can reduce the overall compound

cost without a significant loss in compound properties

• The higher loading ability of Thermax® improves the

impermeability of the compound by replacing polymer with
impermeable filler

• Thermax can raise the viscosity of the compound making it

easier and less expensive to process

• Improved adhesion can be achieved with Thermax® which is

very important for inner liner and other rubber to rubber
bonding applications.

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 Questions & Answers
65 Cancarb July 3, 2019