Vulcanization: New Focus on a Traditional Technology by Small-Angle Neutron Scattering

Octylamine regulating the mechanical robustness of natural rubber by involving in the construction of crosslinking network

The formation of three dimensional network structure is critical in determining mechanical properties of natural rubber (NR). Consequently, it is vital to regulate crosslinking network of NR by controlling vulcanization process. Inspired by our previous studies on contribution of non-rubber components (NRCs) to the excellent properties of NR, we find octylamine in NRCs decreases the activation energy (Ea) of vulcanization from 82.73 kJ/mol to 44.34 kJ/mol, thereby reducing vulcanization time from 18.67 min to 2.71 min. From microscopic perspective, octylamine tends to coordinate with zinc ions to improve dispersion of ZnO in NR. And octylamine promotes ring-opening reaction of S8 to favor formation of polysulfide intermediates. Therefore, the incorporation of octylamine remarkably improves vulcanization efficiency, which contributes to the formation of a more homogeneous network with higher crosslinking density, enhancing remarkably the strength and toughness of NR. As a result, the tensile strength and fracture energy of samples are as high as 31.15 MPa and 68.88 kJ/m2, respectively. In addition, even with a 60 % reduction in ZnO content, the NR samples still maintain high vulcanization efficiency and excellent mechanical properties after the addition of octylamine, which provides a green and feasible way to alleviate the environmental pollution caused by ZnO.

Phosphonium Ionic Liquid-Activated Sulfur Vulcanization: A Way Forward to Reduce Zinc Oxide Levels in Industrial Rubber Formulations

Extensive use of zinc oxide and accelerators such as diphenyl guanidine (DPG) in the vulcanization of rubber composites entail potential environmental risks. These are pervasive contaminants of roadway runoff originating from tire wear particles (TWPs). Herein, the effect of phosphonium ionic liquids (PILs) in styrene-butadiene rubber compounds was demonstrated with reduced ZnO loading and no DPG to minimize the environmental footprint of the vulcanization process. The structure and chemistry of PILs were found to be the influencing parameters impelling the cross-linking kinetics, enabling shorter induction times. The generation of active Zn²⁺ sites by PILs was examined through FTIR spectroscopy, calorimetry, and molecular dynamics simulations. From a tire application perspective, the PILs not only enhanced the cure kinetics but also improved the dynamic-mechanical behavior of the rubber composites. Consequently, the harm caused by TWPs to the atmosphere, fuel intake, and CO₂ emissions was minimal, thereby confirming the potential use of PILs in the tire industry.

Effects of organic components in cuttlebone on the morphological and mechanical properties of peroxide cross-linked cuttlebone/natural rubber composites

The clarification of the role of organic components in cuttlebone particles on the morphological and mechanical properties in terms of the strain-induced crystallization (SIC) of peroxide cross-linked cuttlebone/natural rubber (NR) composites was revealed for the first time in this study. The organic components in cuttlebone particles affected the increased bound rubber layers and the decreased rubber chain orientation due to the formation of interfacial interactions (filler-to-filler and/or filler-to-rubber interactions). During SIC, the presence of organic components in cuttlebone particles did not significantly affect the crystallinity index and crystallite size in cuttlebone/NR composites. The increased moduli in the stress–strain curve resulted from the presence of biofiller, SIC, and organic components in the cuttlebone. Therefore, the presence of organic components in biofiller is an important factor in improving the mechanical properties of green rubber composite materials.

The role of organic components in cuttlebone particles on the morphological and mechanical properties in terms of the strain-induced crystallization of peroxide cross-linked cuttlebone/NR composites was revealed for the first time in this study.

Preparation and Characterization of Diene Rubbers/Silica Composites via Reactions of Hydroxyl Groups and Blocked Polyisocyanates

To improve the curing reaction rate and efficiency of sulfur-cured diene-based rubbers, the introduction of some chemical compounds as activators and accelerants is inevitably required, causing potential harm to humans and ecological systems. Moreover, silica is usually employed as a green filling material for rubber reinforcement, and a silane coupling agent is always required to improve its dispersion. Herein, we reported an effective method to cure hydroxyl-functionalized rubbers/silica composites with blocked polyisocyanates, avoiding the use of any other additives. The enhanced dispersion of silica by interaction with hydroxyl groups on molecular chains endowed the composites with high-mechanical performance. The mechanical properties and crosslinking kinetics of the resultant silica composites can be regulated by adjusting the content of hydroxyl groups in the rubber, as well as the amount of the blocked polyisocyanates. The dynamic heat build-up was related to the distance between crosslinking points. A SBROH/B-TDI/silica composite prepared with blocked toluene diisocyanatem (TDI) exhibited comparable tanδ (0.21 at 0 °C and 0.11 at 60 °C) to that of silica composites cured by sulfur with the help of a silane coupling agent (SBR/S/Si69/silica, 0.18 and 0.10), suggesting great applicable potential for new tire rubber compounds.

Facile strategy to incorporate amidoxime groups into elastomers toward self-crosslinking and self-reinforcement

Amidoxime modification of NBR and the formation of a multi-crosslinking network structure by self-crosslinking of AO-NBR.

Analyses of hierarchical structures in vulcanized SBR rubber by using contrast-variation USANS and SANS

The hierarchical structures of poly(styrene-ran-butadiene) (SBR) rubber vulcanized with sulfur in a swollen state were investigated by using the contrast-variation ultra-small-angle neutron scattering (USANS) and small-angle neutron scattering (SANS) techniques. The following three levels of hierarchical structure were found: (i) ZnO clusters surrounded by dense SBR networks of the order of 1000 Å in size, (ii) dense networks of SBR in the size range of 70–100 Å and (iii) a mesh size of the network of the order of 10 Å. In addition to the three kinds of structure, dense networks without ZnO of the order of 1000 Å were also observed. These last networks were formed by ZnO's reaction with sulfur. However, the ZnO clusters disappeared, which is associated with the diffusion of Zn.

Heterogeneity Effects in Highly Cross-Linked Polymer Networks

Despite their level of refinement, micro-mechanical, stretch-based and invariant-based models, still fail to capture and describe all aspects of the mechanical properties of polymer networks for which they were developed. This is for an important part caused by the way the microscopic inhomogeneities are treated. The Elastic Network Model (ENM) approach of reintroducing the spatial resolution by considering the network at the level of its topological constraints, is able to predict the macroscopic properties of polymer networks up to the point of failure. We here demonstrate the ability of ENM to highlight the effects of topology and structure on the mechanical properties of polymer networks for which the heterogeneity is characterised by spatial and topological order parameters. We quantify the macro- and microscopic effects on forces and stress caused by introducing and increasing the heterogeneity of the network. We find that significant differences in the mechanical responses arise between networks with a similar topology but different spatial structure at the time of the reticulation, whereas the dispersion of the cross-link valency has a negligible impact.

Enhancing the Performance of Rubber with Nano ZnO as Activators

The vulcanization of rubber is a chemical process to improve the mechanical properties by cross-linking unsaturated polymer chains. Zinc oxide (ZnO) acts as an activator, boosting the rubbers' sulfur vulcanization. Maintaining the level of ZnO content in the rubber compounds as low as possible is desirable, not only for economic reasons but also to reduce the environmental footprint of the process. In this contribution, octylamine (OA) capped ZnO nanoparticles (5 nm diameter), prepared through a thermal decomposition method, were demonstrated to be efficient activators for the sulfur vulcanization of natural rubber, enabling the reduction of the required amount of ZnO as compared to commercial systems. The effect of different ZnO activators (OA capped ZnO/commercial indirect process ZnO) on the curing characteristics, cross-linking densities, and mechanical performance, as well as the thermal behavior of rubber compounds, were investigated. Compared to the commercial indirect process ZnO, OA capped ZnO nanoparticles not only effectively enhanced the curing efficiency of natural rubber but also improved the mechanical performance of the composites after vulcanization. This was interpreted as, by applying the OA capped ZnO nanoparticles, the ZnO levels in rubber compounding were significantly reduced under the industrial vulcanization condition (151 °C, 30 min).

Design of next-generation cross-linking structure for elastomers toward green process and a real recycling loop

Currently adopted cross-linking methods in rubber industry are suffering from variable persistent issues, including the utilization of toxic curing packages, release of volatile organic compounds (VOCs) and difficulties in the recycling of end-of-life materials. It is of great importance to explore a green cross-linking strategy in the area. Herein, we report a new "green" strategy based on hydrolyzable ester cross-links for cross-linking diene-typed elastomers. As a proof of concept, a commercial carboxylated nitrile rubber (XNBR) is efficiently cross-linked by a bio-based agent, epoxidized soybean oil (ESO), without any toxic additives. ESO exhibits an excellent plasticization effect and excellent scorch safety for XNBR. The cross-linking density and mechanical properties of the ESO-cured XNBR can be manipulated in a wide range by changing simply varying the content of ESO. In addition, zinc oxide (ZnO) performs as a catalyst to accelerate the epoxide opening reaction and improve the cross-linking efficiency, serving as reinforcement points to enhance the overall mechanical properties of the ESO-cured XNBR. Furthermore, the end-of-life elastomer materials demonstrate a closed-loop recovery by selectively cleaving the ester bonds, resulting in very high recovery of the mechanical performance of the recycled composites. This strategy provides an unprecedented green avenue to cross-link diene elastomers and a cost-effective approach to further recycle the obtained cross-linked elastomers at high efficiency.

Decoupling the Contributions of ZnO and Silica in the Characterization of Industrially-Mixed Filled Rubbers by Combining Small Angle Neutron and X-Ray Scattering

Scattering techniques with neutrons and X-rays are powerful methods for the investigation of the hierarchical structure of reinforcing fillers in rubber matrices. However, when using only X-ray scattering, the independent determination of the filler response itself sometimes remains an issue because of a strong parasitic contribution of the ZnO catalyst and activator in the vulcanization process. Microscopic characterization of filler-rubber mixtures even with only catalytic amounts of ZnO is, therefore, inevitably complex. Here, we present a study of silica aggregates dispersed in an SBR rubber in the presence of the catalyst and show that accurate partial structure factors of both components can be determined separately from the combination of the two scattering probes, neutrons, and X-rays. A unique separation of the silica filler scattering function devoid of parasitic catalyst scattering becomes possible. From the combined analysis, the catalyst contribution is determined as well and results to be prominent in the correction scheme. The experimental nano-structure of the ZnO after the mixing process as the by-product of the scattering decomposition was found also to be affected by the presence or absence of silica in the rubber mixture, correlated with the shear forces in the mixing and milling processes during sample preparation. The presented method is well suited for studies of novel dual filler systems.

Effect of fatty acids on the accelerated sulfur vulcanization of rubber by active zinc/carboxylate complexes

The effect of fatty acids with different aliphatic chain lengths on the accelerated vulcanization reaction of isoprene rubber was investigated through the generation of new intermediates composed of dinuclear bridging bidentate zinc/carboxylate complexes. Using the combination of in situ time-resolved Fourier-transform infrared spectroscopy and in situ time-resolved zinc K-edge X-ray absorption fine structure spectroscopy, the essential complex structure of the intermediates formed during the vulcanization reaction of isoprene rubber was determined to be independent of the aliphatic chain length of fatty acids. However, the reactivity of arachidic acid with ZnO was found to be low, which prolonged the induction period and curing time, and slowed down the curing rate in the vulcanization of isoprene rubber. These results help to understand the complicated vulcanization reaction of rubber, especially natural rubber, which inherently contains various fatty acids. The results obtained in this study are important for developing well-designed high-performance natural rubber products in the future.

The effect of fatty acids with different aliphatic chain lengths on the accelerated vulcanization reaction of isoprene rubber was investigated through the generation of new intermediates composed of dinuclear bridging bidentate zinc/carboxylate complexes.

Zinc-Based Curing Activators: New Trends for Reducing Zinc Content in Rubber Vulcanization Process

The efficiency of sulfur vulcanization reaction in rubber industry is generally improved thanks to the combined use of accelerators (as sulphenamides), activators (inorganic oxides), and co-activators (fatty acids). The interaction among these species is responsible for the formation of intermediate metal complexes, which are able to increase the reactivity of sulfur towards the polymer and to promote the chemical cross-links between the rubber chains. The high number of species and reactions that are involved contemporarily in the process hinders the complete understanding of its mechanism despite the long history of vulcanization. In this process, ZnO is considered to be the most efficient and major employed activator and zinc-based complexes that formed during the first steps of the reaction are recognized to play a main role in determining both the kinetic and the nature of the cross-linked products. However, the low affinity of ZnO towards the rubber entails its high consumption (3–5 parts per hundred, phr) to achieve a good distribution in the matrix, leading to a possible zinc leaching in the environment during the life cycle of rubber products (i.e., tires). Thanks to the recent recognition of ZnO ecotoxicity, especially towards the aquatic environment, these aspects gain a critical importance in view of the urgent need to reduce or possibly substitute the ZnO employed in rubber vulcanization. In this review, the reactivity of ZnO as curing activator and its role in the vulcanization mechanism are highlighted and deeply discussed. A complete overview of the recent strategies that have been proposed in the literature to improve the vulcanization efficiency by reducing the amount of zinc that is used in the process is also reported.

Necessity of two-dimensional visualization of validity in the nanomechanical mapping of atomic force microscopy for sulphur cross-linked rubber

The importance of the two-dimensional (2D) visualization of validity for nanomechanical mapping in atomic force microscopy (AFM) for sulphur cross-linked rubber is emphasized for accurately interpreting the nanoscale physical properties on the surface of the soft material. The “R-factor,” evaluated to be the difference between the experimental and theoretical force–deformation curves, was considered to be the reliability index of the AFM analysis for all data points on the sample surface. A small R-factor corresponds to high accuracy. The advantage of the R-factor mapping method is demonstrated using nanomechanical mapping data of the inhomogeneous isoprene rubber network by the Johnson–Kendall–Roberts and the Derjaguin, Muller, and Toporov contact mechanics models. The 2D R-factor mapping clearly and correctly supported the roles of sulphur cross-linking reagents to control the network morphology of vulcanizates. Additionally, the blanket effect, which is induced by the rubber layer on the hard part and influences experimental force–deformation curves, is firstly proposed in this study. Nanomechanical mapping with 2D reliability indexes is expected to contribute to an advance in AFM studies on soft matter such as rubber materials, leading to a more accurate understanding of the structural characteristics of the rubber networks. Thus, this validity confirmation method is necessary for developing rubber science and technology.

The two-dimensional visualization of validity for nanomechanical mapping in atomic force microscopy for sulphur cross-linked rubber is emphasized for accurately interpreting the nanoscale physical properties on the surface of the soft material.

VULCANIZATION CHARACTERISTICS OF NATURAL RUBBER COAGULATED BY MICROORGANISMS

The network variations of natural rubber (NR) during the vulcanization process were investigated by 1H chemical shift by liquid-state 1H nuclear magnetic resonance (NMR) spectroscopy. NR latex coagulated by microorganisms (NR-m) was contrasted with NR latex coagulated by acid (NR-a). The influences of the coagulation process on the structures, vulcanization characteristics, and mechanical properties of NR were analyzed. The results show that the cross-link density (XLD) and mass percentage of cross-link network (A(Mc)) can be increased with the increment of the vulcanization time; while the mass percentage of dangling free ends of the hydrocarbon and small molecules (A(T2)), the longitudinal relaxation time (T1), transverse relaxation time (T2), and molecular mass of inter–cross-link chains (Mc) decreased with the prolonging of vulcanization time both NR-m and NR-a. NR-m exhibits shorter scorch times (ts1, ts2) and optimum cure time (t90) and shows higher maximum torque (MH) and minimum torque (ML) than that of NR-a. It is obvious that the higher XLD and A(Mc) and lower A(T2), T1, T2, and Mc values of NR-m result in higher stress, tensile strength, and tear strength of NR compounds.

Dominant formation of disulfidic linkages in the sulfur cross-linking reaction of isoprene rubber by using zinc stearate as an activator

A linear combination fitting in sulfur K-edge X-ray absorption near edge structure (S-XANES) measurements reveals each fraction of monosulfidic, disulfidic and polysulfidic linkages in solvent extracted sulfur cross-linked isoprene rubbers. The sulfidic linkage of a disulfidic type is found for the first time to be dominant when zinc stearate and N-(1,3-benzothiazol-2-ylsulfanyl)cyclohexanamine are used as the activator and accelerator, respectively, for the sulfur cross-linking reaction at 140 °C. The presence of the bridging bidentate zinc/stearate complex as an intermediate for the sulfur cross-linking reaction is supposed to induce the generation of abundant disulfidic linkages in the rubber networks. This unexpected observation is of use for the material design of high performance rubber products with anti-aging and thermal stabilities. S-XANES is a powerful tool that was used to reveal the characteristics of the sulfur cross-linking of rubber. These results will contribute to the development of rubber science and technology.

The bridging bidentate zinc/stearate complex, an intermediate for the sulfur cross-linking reaction, supposedly induces an abundance of disulfidic linkages in the rubber network.

INVESTIGATION OF THE VULCANIZATION CHARACTERISTICS OF NATURAL RUBBER COAGULATED BY MICROORGANISMS

The network variations of NR during the vulcanization process were investigated by 1H chemical shift by liquid-state 1H-NMR spectroscopy. NR latexes coagulated by microorganisms (NR-m) or acid (NR-a) were contrasted. The influences of coagulation on the structures, vulcanization characteristics, and mechanical properties of NR were analyzed. The results show that the cross-link density (XLD) and mass percentage of cross-link network [A(Mc)] increased with the increment of the vulcanization time, whereas the mass percentage of bangling free ends of the hydrocarbon and small molecules [A(T2)], the longitudinal relaxation time (T1), the transverse relaxation time (T2), and the molecular mass of inter–cross-link chains (Mc) decreased with the prolonging of vulcanization time for both NR-m and NR-a. Although NR-m exhibits shorter scorch times and optimum cure time, it shows higher maximum torque and minimum torque than that of NR-a. It is obvious that the higher XLD and A(Mc), the lower the A(T2), T1, T2, and Mc values of NR-m, resulting in higher stress, tensile strength, and tear strength of NR compounds.