Mixing, elastomers

Rubber Reclaimers Association (RRA) cure test recipe for mixed elastomer and NR reclaim cured 20 min at 141°C. 

Mixing elastomers, carbon blacks, and chemicals to form the rubber compound. 

Intensive mixing is used to produce elastomer intermediates, especially to mix in fillers and other polymer additives or to mix elastomers. Heavy Banbury mixers with quite high shear gradients are used. 

Internal mixing (Banbury mixing) serves to produce intermediate products from elastomers and is used in particular to work in fillers, mix elastomers, etc. 

Fig. 17.26 SEM images of PP/EPDM/Si02 ((80/20/3) (a and b) and PP-g-MA/EPDM/Si02 (80/20/3) (c and d) ternary composites prepared using hydrophilic silica (a and c) one-step simultaneous mixing and (b and d) two-step mixing (elastomer and the filler were mixed by means of a two-roll mill at room temperature for 10 min to get masterbatch first, and then the masterbatch was melt blended with pure PP or PP-g-MA) (Yang et al. 2007)...

Kim, J. K. and White, J. L., An experimental and theoretical study of starvation effects on flow and mixing elastomers in an internal mixer, Nihon Reoloji Gakkaishi 77 203 (1989). 

Paterrt Nrrmber EP 1005969 A1 20000607 ROTOR FOR MIXING ELASTOMERS HAVING A VARIABLE FLANGE OR FLIGHT ANGLE... 

Mix elastomers such as ABS or EPDM that act as toughening agents... 

Considerable work has also been conducted to try to find thermoplastic elastomers that can be used to simplify processing by enabling dry blending and melt casting instead of the conventional mixing and curing process (see Elastomers, synthetic). 

The elastomer process is very similar to the Dennis process. It involves a number of steps in which a gas, formerly carbon dioxide and now fluorocarbon, is mixed with a plastisol under pressure. When released to atmospheric pressure, the gas expands the vinyl compounds into a low density, open-ceUed foam which is then fused with heat. 

Properties. One of the characteristic properties of the polyphosphazene backbone is high chain dexibility which allows mobility of the chains even at quite low temperatures. Glass-transition temperatures down to —105° C are known with some alkoxy substituents. Symmetrically substituted alkoxy and aryloxy polymers often exhibit melting transitions if the substituents allow packing of the chains, but mixed-substituent polymers are amorphous. Thus the mixed substitution pattern is deUberately used for the synthesis of various phosphazene elastomers. On the other hand, as with many other flexible-chain polymers, glass-transition temperatures above 100°C can be obtained with bulky substituents on the phosphazene backbone. 

Oxidation Catalysis. The multiple oxidation states available in molybdenum oxide species make these exceUent catalysts in oxidation reactions. The oxidation of methanol (qv) to formaldehyde (qv) is generally carried out commercially on mixed ferric molybdate—molybdenum trioxide catalysts. The oxidation of propylene (qv) to acrolein (77) and the ammoxidation of propylene to acrylonitrile (qv) (78) are each carried out over bismuth—molybdenum oxide catalyst systems. The latter (Sohio) process produces in excess of 3.6 x 10 t/yr of acrylonitrile, which finds use in the production of fibers (qv), elastomers (qv), and water-soluble polymers. 

Organophosphoms compounds, primarily phosphonic acids, are used as sequestrants, scale inhibitors, deflocculants, or ion-control agents in oil wells, cooling-tower waters, and boiler-feed waters. Organophosphates are also used as plasticizers and flame retardants in plastics and elastomers, which accounted for 22% of PCl consumed. Phosphites, in conjunction with Hquid mixed metals, such as calcium—zinc and barium—cadmium heat stabilizers, function as antioxidants and stabilizer adjutants. In 1992, such phosphoms-based chemicals amounted to slightly more than 6% of all such plastic additives and represented 8500 t of phosphoms. Because PVC production is expected to increase, the use of phosphoms additive should increase 3% aimually through 1999. 

Chlorosulfonated Polyethylene. This elastomer is made by the simultaneous chlorination and chlorosulfonation of polyethylene in an inert solvent. The resulting polymer is an odorless, colorless chip that is mixed and processed on conventional mbber equipment. The polymer typically contains 20-40% chlorine and 1% sulfur groups (see ElASTOL RS, SYNTHETIC-Cm OROSULFONATEDPOLYETHYLENE) (8). 

Urethanes are processed as mbber-like elastomers, cast systems, or thermoplastic elastomers. The elastomer form is mixed and processed on conventional mbber mills and internal mixers, and can be compression, transfer, or injection molded. The Hquid prepolymers are cast using automatic metered casting machines, and the thermoplastic peUets are processed like aU thermoplastic materials on traditional plastic equipment. The unique property of the urethanes is ultrahigh abrasion resistance in moderately high Shore A (75—95) durometers. In addition, tear, tensUe, and resistance to many oUs is very high. The main deficiencies of the urethanes are their resistance to heat over 100°C and that shear and sliding abrasion tend to make the polymers soft and gummy. 

The largest segment of the CASE family of polyurethanes are elastomers. Cast polyurethane elastomers reached a new dimension when high pressure impingement mixing led to reaction injection molding (RIM). This technology is used widely in the automotive industry, and reinforced versions (RRIM) and stmctural molded parts (SRIM) have been added in more recent years. 

When 4-(mercaptoacetamido)diphenylamine [60766-26-9] (39) is added to EPDM mbber and mixed in a torque rheometer for 15 minutes at 150°C, 87% of it chemically binds to the elastomer (24). The mechanical and thermal stress placed on the polymer during mixing mptures the polymer chain, producing radicals that initiate the grafting process. 

In order to "cure" or "vulcanize" an elastomer, ie, cross-link the macromolecular chains (Fig. 2), certain chemical ingredients are mixed or compounded with the mbber, depending on its nature (4,5). The mixing process depends on the type of elastomer a high viscosity type, eg, natural mbber, requires powerhil mixers (such as the Banbury type or mbber mills), while the more Hquid polymers can be handled by ordinary rotary mixers, etc (see Rubber... 

An entirely new concept was iatroduced iato mbber technology with the idea of "castable" elastomers, ie, the use of Hquid, low molecular-weight polymers that could be linked together (chain-extended) and cross-linked iato mbbery networks. This was an appealing idea because it avoided the use of heavy machinery to masticate and mix a high viscosity mbber prior to mol ding and vulcanization. In this development three types of polymers have played a dominant role, ie, polyurethanes, polysulftdes, and thermoplastic elastomers. 

Mixing. Ethylene—acrylic elastomers are processed in the same manner as other elastomers. An internal mixer is used for large-scale production and a mbber mill for smaller scales. In either case, it is important to keep the compound as cool as possible and to avoid overmixing. Ethylene—acryflc elastomers require no breakdown period prior to addition of ingredients. Mixing cycles for a one-pass mix are short, typically 2.5—3.5 min. When compounds are mixed on a mbber mill, care should be taken to add the processing aids as soon as possible, after the polymer has been banded on the mill. Normal mill mixing procedures are followed otherwise. 

Considerable amounts of EPM and EPDM are also used in blends with thermoplastics, eg, as impact modifier in quantities up to ca 25% wt/wt for polyamides, polystyrenes, and particularly polypropylene. The latter products are used in many exterior automotive appHcations such as bumpers and body panels. In blends with polypropylene, wherein the EPDM component may be increased to become the larger portion, a thermoplastic elastomer is obtained, provided the EPDM phase is vulcanked during the mixing with polypropylene (dynamic vulcani2ation) to suppress the flow of the EPDM phase and give the end product sufficient set. 

The polymei latex is then coagulated by addition of salt oi acid, a combination of both, oi by a fiee2e—thaw process. The cmmb is washed, dewatered, and dried. Since most fluorocarbon elastomer gums are sold with incorporated cure systems, the final step in the process involves incorporation of the curatives. This can be done on a two-roU mill, in an internal mixer, or in a mixing extmder. 

Internal mixing is widely used with fluorocarbon elastomers. Gumstocks and compounds that are particularly successful fall in the viscosity ranges discussed earlier, and use both incorporated bisphenol-type and peroxide cure systems. A typical internal mix cycle mns 6—8 min with a drop temperature of 90—120°C. The typical formulations in Tables 4 and 7 are readily mixed in an internal mixer. 

J. W. Graham, Neoprene n Overview of Properties, Mixing and Compounding, Du Pont Elastomers Informal Bulletin, C-NP-050.044, E. I. du Pont de... 

Epichlorohydrin Elastomers without AGE. Polymerization on a commercial scale is done as either a solution or slurry process at 40—130°C in an aromatic, ahphatic, or ether solvent. Typical solvents are toluene, benzene, heptane, and diethyl ether. Trialkylaluniinum-water and triaLkylaluminum—water—acetylacetone catalysts are employed. A cationic, coordination mechanism is proposed for chain propagation. The product is isolated by steam coagulation. Polymerization is done as a continuous process in which the solvent, catalyst, and monomer are fed to a back-mixed reactor. Pinal product composition of ECH—EO is determined by careful control of the unreacted, or background, monomer in the reactor. In the manufacture of copolymers, the relative reactivity ratios must be considered. The reactivity ratio of EO to ECH has been estimated to be approximately 7 (35—37). 

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