EBB 220/3

ELASTOMER & LATEX

Introduction
Introduction

The words rubber come from the materials

from the rubber tree name Havea
Brasiliensis

The different between raw rubber

vulcanized rubber or elastomer:

and

1. Raw

rubber either natural rubber or synthetic

rubber are materials that has plastic
properties and can be reshaping at high
temperature and not sutaible for applications.

1. Elastomer

is the words that used for

vulcanized rubber, vulcanisate or crosslinking
rubber

Raw
Raw rubber
rubber vs
vs Elastomer
Elastomer

Raw rubber no crosslinking

Elastomer crosslinking

In beginning all product from rubber are

made from natural rubber that produced
from materials from natural rubber tree
called latex.

Synthetic rubber are produced from

reactions of low molecular weight
materials called monomer to produced
long chain molecule called polymer

Elastic properties are produced by mix

raw rubber with specific additives during
rubber compounding

When rubber was heated the chemical reactions

occur call vulcanization or curing.

Process were rubber molecules were tied together

at specific place called crosslinks

The crosslinks will prevent the slippaged of

molecules.

Elastomer are elastic materials that can deformed

when forced being applied and back to the original
shape when release the forced.

The words
polymer.

elastomer

comes

from

elastic

Function
Function of
of crosslinks
crosslinks

Stretch

Retract

Rubber
Rubber processing
processing
Raw Rubber
Mastication process
Compounding
Rubber Compound
Forming process
Vulcanization process
Vulcanize rubber/
End product

Mastication
Mastication Process
Process

Mastication is mechanical shearing process

using two roll mill or internal mixer) for
Reduced the molecular weight,
Reduced the viscosity and
To soften the raw rubber.

After mastication the processing will be

much easier and increased the effectiveness
of dispersions of compounding ingredients.

The mastication is compulsory for natural

rubber due to high molecular weight in nature
(around 105-106 )

Compounding
Compounding Process
Process
Rubber

compounding is the way of

making useful products from raw
rubber

The

process involved the addition of

additives to change the masticated raw
rubber to rubber compound before a
forming process.

The

compounding process used the

two roll mill and internal mixer

General
Generalrubber
rubbercompounding
compoundingformulation
formulation

Elastomer/ Raw rubber

Fillers
Softener
Antioxidant
Asid Stearic
Zinc Oxide
Accelerator
Sulphur
Total
** Parts

100
50
5
1
1
5
1
2
165

per hundred rubber (pphr) All the ingredients

used in a compound formulation are normally given in
amounts based on a total of 100 parts of the rubber or
combination of rubber used.

Compounding
Compounding Ingredients
Ingredients

Each ingredient has a specific function either in

processing, vulcanization or end use of the products.

The various ingredients may be classified according

to their specific functions in the following groups:

1.

Fillers
Carbon black or non black fillers

2.

Plasticizers or softeners
Extenders, processing aids, special plasticizers

3.

Age resistors or antidegradants

Antioxidants, antiozonants, special age resistors

4.

Vulcanizing or curing ingredients

vulcanization agents , accelerators and activator

5.

Special-purpose ingredients
Coloring pigments, blowing agents,
antistatics agents retarders, peptizers

flame

retardants,

Sulphur
Sulphur vulcanization
vulcanization

The crosslinking produced can have a monosulphide

and polysulphide or both depending on the
vulcanization systems used

Sulphur vulcanization systems can be divided into 3

systems depending on the relative amount of sulphur
& accelerator used.

The three systems can be differentiate through the

types of crosslinking produced and the main chain
modification after vulcanization

Network structure of sulphur vulcanizate

Sulphur
Sulphur vulcanization
vulcanization systems
systems
System

Conventional
vulcanization (CV)

Sulphur content
(pphr)

Accelerator
contents (pphr)

2.0-3.5

1.0-0.5

Semi- Efficient
1.0-2.0
vulcanization (semi-EV) (or sulphur donor)

2.5-1.0

Efficient vulcanization
(EV)

6.0-2.0

0.-1.0
(or sulphur donor)

Sulphur donor sulphur vulcanization

systems without sulphur but gives a sulphur
during vulcanization

Efficient
vulcanization

Conventional
vulcanization

Forming
Forming Process
Process

After all compounding ingredients have

been properly mixed
the compounded
green stock is tacky and thermoplastics

In this plastic condition, the stock can be

shaped by the applications of force.

This can be accomplished for example, by

squeezing it betweens rolls (calendering) or
pushing through an orifice having the desired
shape (tubing or extruding).

Vulcanization
Vulcanization Process
Process
After the green stock has been formed to the desired
shape, it needs to be converted to an elastic materials
vulcanization process usually under pressure at elevated
temperature using different techniques such as
Press vulcanization
Open vulcanization
Continuous vulcanization
Chemically the process involves insertation of crosslinks
between the polymer macromolecules through the actions
of vulcanizing ingredients.
The crosslinking of rubber also referring as curing it a
process whereby a raw materials is converted into a useful
product.

Compression
Compression Moulding
Moulding Process
Process

Press vulcanization takes place in press that

supply heat and pressure.

A vulcanizing press consists essentially of two

or more plates that can be bought together
and separated by hydraulic pressure heated
by steam or electricity

The rubber articles are vulcanized in various

moulds between the heated plates under
pressure.

In its simplest form, a mould consists of two

metal plates with cavities conforming to the
outside shape of the desired finished part.

Molding press

Compression
Compression Moulding
Moulding

Most of rubber products produced using this method.

Rubber compound is placed in each cavity of the mold

and closed and placed in hydraulic press.

Under the applied of hydraulic pressure (4-6 MPa) at

elevated temperature (140-200C) using the cure time
obtained from rheometer curve.

After mould is closed the stock will flow and

completely fill the mould cavity

The mould is maintained closed under pressure for a

prescribed time at particular moulding temperature
the mould is then removed from the press and opened
to remove the moulded part.

Before

After

Finishing
Finishing Process
Process

Many rubber articles require finishing operations after

vulcanization.

For example, the flash attached to moulded parts must be

removed before the parts are ready for use carried out by
hand trimming using scissors or knives.

Some rubber parts are painted to give them an attractive

finish or more often to protect against ozone, oils, acids,
chemicals ant the like. The paints are usually rubber based.

Items such as seals and windshield wiper blades may

require surface treatment with chlorine, bromine or fluorine
in water. The halogenated surface will have lower friction
than the untreated surface while the bulk will be unaffected.

The finishing operations of extruded articles include coiling,

cutting to specific length and washing.

Quality
Quality Control
Control

Quality control is necessary to ensure the

quality of final products

During various stages, checking will be

performed on incoming materials, in process
materials and finished products.

The rubber manufacturer usually test the raw

materials to make sure that they are uniform
and of adequate quality

Control test are applied to various steps in

the manufacturing process. The test
employed are sensitive to any change in the
rubber compound resulting from errors.

Example of errors
1.
2.
3.
4.
5.

faulty compounding ingredients,

poor dispersion,
improper temperature control,
wrong sequence of addition
too short or too long mixing cycles.

The control scheme utilize mostly standardized

physical tests on both unvulcanized and vulcanized
rubber compounds.
1.

Unvulcanized compound tests measurement of the

viscosity, scorch time and cure rate.

1.

Vulcanized compound tests measurements density,

hardness, tensile modulus, tensile strength and
elongation at break.

Materials

Function

Elastomer/raw rubber

Basic components in rubber compounding

Fillers

Used for reinforced or modified the mechanical

properties and also to reduced the cost

Plasticier

To ease the processing, to modify the specific

properties and also as extender

Anti oxidant

To protect the rubber from ageing

Accelerator

To increase vulcanization process and reduced the

time of vulcanization

Activator

To increased the accelerator efficiency

Vulcanization agent

Needed during vulcanization process to produced a

crosslinking

Other ingredients

Used for specified purpose such as for coloring, as

retarder etc

Process

Function

Mastication

Mechanical shearing process to reduced the

molecular weight, viscosity and to soften the
rubber.

Compounding

Process of addition the rubber additives to

convert the raw rubber into rubber compound.

Forming

Process of convert the rubber compound into a

required size and shape with a forced.

Vulcanization

Process of convert the shape product to an

elastic materials with formation a crosslinking
under temperature and pressure

Final Operation

Final operation after vulcanization such as

trimming, paint or surface treatment

Quality Control

To ensure the quality of final product

Latex
Latex processing
processing
Raw Latex
Latex compounding

Compounded Latex
Latex curing
Latex processing
Vulcanize latex/
End product

Introduction
Introduction

Latex is defined as a dispersion of polymer

in an aqueous medium which is a
dispersion of polymeric solids in water

Latex has two phases:

1.

The dispersed phase or discontinues phase

consisting of small particles of polymers
(particle size < 5 micrometer in diameter)

2.

The dispersion medium or the continuous phase

or serum (a dilute aqueous solution)

Classification
Classification of
of latices
latices

Latices are classified as:

1.

Natural latices obtain from plants

2.

Synthetic latices produced

emulsion polymerization process

3.

Artificial latices produced by dispersing

the appropriate bulk polymer in an aqueous
dispersion medium

4.

Modified latices
produced by
modification of existing type of latex ( by
grafting, crosslinking etc)

from

Natural
Natural rubber
rubber latex
latex concentrate
concentrate

The NR latex obtained from the plantation is called

fresh or field latex

The field latex contains about 33% NR and thus not

economical to be used to make a latex products

The rubber content of the field latex need to be

increased before it is used in making latex products.

This is achieved by doing concentration process to

the field latex

There are few methods that can be used to

concentrate natural rubber latex:
1.
2.
3.

Concentration by creaming
Concentration by centrifugation
Concentration by evaporation

Preservations
Preservations for
for latex
latex concentrate
concentrate

Preservation is necessary to prevent micro-organism from

attacking the non-rubber components of latex.

Latex which has been attacked by micro-organism has lower

colloidal stability and bad odour.

Concentrated latex is preserved for long-term storage. The

most popular preservative is ammonia.

There are two types ammonia preservation systems:

Low -ammonia latex (LA latex)

0.2 % m/m ammonia.

short term preservation
suitable for certain applications such as latex foam requires low
ammonia content in order for to gel properly.
secondary preservatives are added to LA latex for long term storage.

High ammonia latex (HA latex):

0.6 - 0.8 % m/m of ammonia

long term preservation

Investigation
Investigation Latex
Latex Poperties
Poperties

The properties of the latex are of interest because:

To gain better understanding of the physical and chemical

nature of the latex.

To determine the fitness of the latex for a particular

application.

To assure the general quality of the latex

The test methods to evaluate latex properties can

be classified into three groups:
1.
2.
3.

Tests related to chemical composition

Tests related to colloidal stability
Tests related to physical properties

Latex
Latex Compounding
Compounding

Process of addition of chemicals

compounding

Latex containing these chemicals compounded latex.

Most chemicals added to the latex ~ in solid form therefore

these chemical need to be dispersed in water first before
added to the latex.

The dispersed chemicals dispersion and prepared by

grinding them together with the dispersing agent in water.

The chemicals used in latex compounding can be divided into

three general classifications:
Surface active agents (surfactants)
2. Liquid phase modifier
3. Elastomer or rubber phase modifier
1.

to the latex

General
Generallatex
latexcompounding
compoundingformulation
formulation

61.7% Elastomer/ Raw latex

10% KOH
50% Sulphur
50% Zinc Oxide
50% Accelerator
50% Antioxidant
60% Fillers

100
0.3
0.5
0.25
0.75
0.5
15

Total

117.3

** Parts

per hundred rubber (pphr) All the ingredients

used in a compound formulation are normally given in
amounts based on a total of 100 parts of the rubber or
combination of rubber used.

Latex
Latex Compounding
Compounding

Process of addition of chemicals

compounding

Latex containing these chemicals compounded latex.

Most chemicals added to the latex ~ in solid form therefore

these chemical need to be dispersed in water first before
added to the latex.

The dispersed chemicals dispersion and prepared by

grinding them together with the dispersing agent in water.

The chemicals used in latex compounding can be divided into

three general classifications:
Surface active agents (surfactants)
2. Liquid phase modifier
3. Elastomer or rubber phase modifier
1.

to the latex

Latex
Latex Curing
Curing

Curing of latex process of introducing cross-links in the

rubber molecules.

The term vulcanisation used to describe cross-linking

process involving sulphur as cross-linking agent.

Two types of vulcanisation in latex:

pre-vulcanisation when the vulcanisation is done while
the latex is still in liquid state.

post-vulcanisation if the vulcanisation is done on latex

film.

Latex that has been pre-vulcanised referred as prevulcanised latex or PV latex (for pre-vulcanised natural rubber
PVNR).

Appearance PVNR very similar to unvulcanised NR with

maintained fluidity.
The cross-linking only takes place in each individual
particles. particles in PVNR have the same shape, size
& size distribution as those in initial unvulcanised latex.

Preparation
Preparationof
ofsulphur-prevulcanised
sulphur-prevulcanisedNR
NRlatex.
latex.
Latex

Stabilisers

Depends on
formulation

Vulcanising agents +
other ingredients

To get desired degree

of vulcanisation
After desired degree of
vulcanisation attained
latex is cooled and run off
into container

Strained & bulked

Vulcanisation
55-80C

Pre-vulcanised latex
Mature for 7 days at normal
ambient temperature
to improve uniformity

Maturation

Processing

Latex is constantly stirred

avoid formation of skin &
sedimentation of ingredients.
Various tests to check degree
of vulcanisation

Latex
Latex Dipping
Dipping Process
Process

Dipping process is used to make thin and hollow latex

products such as gloves, catheters and toys These
products are called dipped products.

In principle dipping process involves dipping cleaned

formers into compounded latex (prevulcanized or
postvulcanized compound)

Latex film will be formed around the former and product

obtained by drying and curing the films.

Latex dipping process can be classified into three methods:

1.

Straight or simple dipping no stabilize agency is

used to form the films

2.

Coagulant dipping a direct coacervant is used to

promote film formation

3.

Heat-sensitized dipping a heat sensitizer is used to

promote film formation

Example
Example of
of the
the exams
exams question
question

Gives the rubber processing flow chart

including the simple definition of the
processes involved.

Gives the general formulation to produce

elastomer
products
with
simple
elaborations ingredients used.

Briefly explain the vulcanization process.

Students
Students Activity
Activity

In 5 minutes try to list how many points

that you remember the differences
between elastomer and latex