Rubber

⮚ Natural rubber
⮚ Crude Rubber
⮚ Compounding of rubber
⮚ Vulcanization of rubber
⮚ Neoprene Rubber
⮚ SBR Rubber
⮚ Nitrile Rubber
⮚ Silicone Rubber
⮚ Reclaimed Rubber
Rubber
⮚High polymer with elastic properties in excess of 300%. On stretching, it elongates up to
200% of its original dimensions and returns to its original form when the force is removed,
⮚ Strength, Hardness & Flexibility,
⮚ Impermeable to air and water; Not attacked atmospheric gases and Chemicals,
⮚ Resistant to cutting, tearing and abrasion over a wide range of temperature,
⮚ Due to plasticity, rubber is pliable and amenable,
⮚ Tackiness- When two fresh surfaces of milled rubber are pressed together, they coalesce.
Natural Rubber
⮚Natural polymer; polymer of isoprene(2-methyl-1, 3-butadiene)
⮚possess elasticity; undergoes long range reversible extension under small applied force
⮚obtained from the latex of rubber trees found in tropical and semi-tropical countries such as
India (southern part), Indonesia, Malaysia, Ceylon, South America, etc.
⮚The latex contains about 25-40% of rubber hydrocarbons dispersed in water along with
stabilizer proteins and some fatty acids. The latex is strained and preserved with NH3.
CH2 = C – CH = CH2 [- CH2 – C = CH – CH2 -]n

CH3 CH3
Isoprene Polyisoprene
2-methyl–1, 3–butadiene (natural rubber)
Crude Rubber
Coagulation
⮚ Rubber is separated from latex by coagulation. Coagulated rubber is white soft mass which
is called Coagulum and it is treated to prepare different forms of Crude Natural rubber.
⮚ The latex is diluted to 15% and coagulation is carried out by removing negative charge on
the emulsion particles by an electrolyte like 1-2% Acetic acid and the rubber hydrocarbon is
coagulated in solid form.
Crude Rubber
⮚ 90-95% Rubber hydrocarbon, 2-4% Proteins, 1-2% Resins.
⮚ Different forms of crude rubber- Crepe rubber, Smoked Sheets, Gutta Percha.
Crepe Rubber
⮚Coagulam is passed through a crepe machine consisting of two rollers with grooves, upon
which water is sprayed.
⮚Retarder such as NaHSO3 added to the coagulum to retard the action of oxidizers,
discoloration and softening of rubber.
⮚ The spongy coagulam When passes through the rollers is converted into a sheet with uneven
rough surface.
Smoked Sheets
⮚Coagulation carries out in a tank with grooves on sides and metal plates along the width.
⮚Diluted latex and acetic acid mixture is stirred thoroughly (with plates removed).
⮚Then plates are inserted into the grooves and tanks are allowed to stand for 16 hour.
⮚ As a result, tough slabs of coagulum formed which are then passed through 3-4 roller
machines to give final rubber sheet.
⮚ The sheets are hung for few hours and then hung in a smoke house at a temperature of
about 40-50˚Cfor 4 days.
⮚The amber coloured crude rubber thus obtained is translucent because of removal of water.
Gutta Percha
⮚ Obtained from matured leaves of Dichopsis gutta and Palaguim gutta.
⮚ The leaves are ground, treated with water at about 65-70˚C for 30 min and then transferred
into cold water.
⮚ This can be obtained in pure form by solvent extraction which makes it free from insoluble
resin and gums.
⮚ Horny and tough in room temp. but soft and tacky when heated to 100 ˚C.
⮚ Soluble in aliphatic hydrocarbons; insoluble in aromatic and chlorinated hydrocarbons.
⮚ It is trans polymer of isoprene.
Drawbacks of Raw Rubber
⮚Brittle at low temperature and becomes very soft at high temperatures (range of use 10-
60℃).
⮚ It is too soft to be used for heavy duty operation. Its tensile strength is only 200 Kg/cm2.
⮚On stretching, it undergoes permanent deformation.
⮚Not resistant to mineral oils, organic solvents and has large water absorption capacity.
⮚On exposure to air, undergoes peroxidation. As a result, durability is decreased.
⮚ Readily attacked by strong oxidizing agents like Conc. HNO3, Conc. H2SO4, ClO2, NaClO,
H2CrO4
⮚ Non-resistant to non-polar solvents such as gasoline, Benzene, CCl4, Vegetable Oils etc.
Compounding of Rubber
Compounding means mixing of the raw rubber with other ingredients so as to impart the
desired properties to the product suitable for particular use.
1. Reinforcing agents
⮚ Improve tensile strength & Provides rigidity,
⮚ Carbon black improves resistance to abrasion,
⮚ Acetylene black produces electrically conducting rubber,
⮚ Ex- ZnO, MgCO3, Carbon black, Soot of ethyl silicate, Clay.
2. Inert fillers
⮚ Improve the hardness, Strength and abrasion resistance, serve as diluents,
⮚Ex- Limestone, talc, soft carbon black, barytes, ZnO.
3. Softeners
⮚ Serve as a lubricants or plasticizers, Provides tenacity and adhesion, Produce tack,
⮚ Ex- Naphthenic oil, Aromatic oil, asphalt, Pine tar, coal tar, vegetable oil, fatty acid, liquid
polymer.
4. Antioxidants
⮚ Protect rubber from the attack of air, heat, light, O3.
⮚Ex- Amine or Phenolic compounds.
5. Colour and Pigments
⮚ To give required colour,
⮚ Ex- TiO2, Cr2O3, Fe2O3, Sb2S3, Pb2O3, Carbon black, Organic lake powder etc.
⮚ Baking powder (NaHCO3) is used in sponge rubber.
6. Vulcanising agent
⮚ S, Se, Te, Sulphur monochloride, Polysulphite Polymers.
7. Accelerator
⮚ To increase rate of vulcanisation of rubber,
⮚ To reduce vulcanisation temperature and amount of S required.
⮚ Ex- Benzothiazyl disulphide, Butyraldehyde anil.
8. Accelerator activators
⮚ To increase the effect of accelerators,
⮚ Ex- ZnO, MgO, Litharge, Stearic acid, Amine Soaps.
9. Peptizers
⮚ To reduce viscosity of rubber,
⮚ Cause chain scissions and decrease molecular weight,
⮚ Ex- Aromatic mercaptants, Thiophenols
Vulcanization of Rubber
⮚Chemical process by which the physical properties of natural or synthetic are improved; finished
rubber has higher tensile strength, sufficient toughness, resistance to swelling and abrasion, and is
elastic over a greater range of temperatures.
⮚ Vulcanisation is carried out by heating crude rubber in presence of S or dipping it in a solution
of S2Cl2 in CS2.
⮚ It depends upon- Amount of sulphur used, Temperature, Duration of heating.
⮚Non-Sulphur Vulcanisation
It is initiated by free radical which is generated from a curing agent such as organic peroxide or
abstraction of β-hydrogen from C=C by the free radical formed. Then this C=C gives rise to a cross-
linked radical which further attacks more C=C to form a large number of such cross-linkages which
are responsible for changes in the properties of rubber. It is carried out by heating with peroxide or
quinones or by exposing the sulphur in gamma radiation.
⮚ Sulphur Vulcanisation
The crude sulphur is mixed with 3% ground sulphur, accelerator(aldehyde amines, thio
carbamets, thiuram sulphides, guanidine, thiozols, thio carbanilide, mercapto thiocarbazole), &
activator; and heated to 150˚C. This process involves the formation of various cross linkages such as
sulphide crosslinks, Disulphide crosslinks, formation of sulphur heterocycle and formation of C-C
crosslinks through the intervention of free radical intermediates or sulphur catalysed
dehydrogenation at selected sites.
⮚Vulcanite or ebonite contain 32% Sulphur.
Vulcanized Rubber
Properties
⮚ Good tensile strength(up to 2000Kg/cm2) and extensibility,
⮚ Improved resilience,
⮚ Low water absorption capacity,
⮚ Resistant to organic solvents such as petrol, CCl4, fats and oils; it swells in these liquids,
⮚ Better electrical insulator,
⮚ Higher resistance to oxidation, abrasion, wear and tear,
⮚ Low tackiness & elasticity,
⮚ Working temperature ranges from -40 to -100˚C,
⮚ Easy to manipulate to give desired shape,
⮚ Lower Very good rapidity of retraction.
Neoprene
Properties
❑ Synthetic rubber (polymer of chloroprene),
❑Resistant to oxidizing agent, Vegetable and mineral oils,
❑ Flexible over a wide range of temperature,
❑ Colorless and UV resistant,
❑ Resistant to sun, climate and ozone deterioration,
❑ Resistant to abrasion and tearing,
❑ Fire retardant-burn point is around 260˚C,
❑ Electric and heat insulation.
Uses
❑ Used as insulator in power transformers, light bulbs, cables & other electrical applications,
❑ Suitable for gloves and other protective wear because of its thermal resistance and
flexibility,
❑ Used in wetsuits and diving suits,
❑ Window & door seals, hose covers, belts, vibration mounts & shock absorber seal contain it,
❑ Used to make supports and braces, such as hand, knee, and elbow supports,
❑ Suited for corrosion resistant coatings,
❑ Used as base adhesive,
❑ Noise isolation in power transformer installation.
Synthesis
Buna S / SBR Rubber
Properties
⮚Very tough and a good substitute for natural rubber,
⮚Possesses high abrasion resistance & load bearing capacity,
⮚ Greater Ozone resistant but lower in crack spread resistance,
⮚Easily oxidized, Swells in oils and solvents,
⮚ Do nit mill, mix or Calendar easily,
⮚ Greater weatherability,
⮚ Deficient in building tack.
Uses
⮚ Used widely in pneumatic tires in shoe heels and soles, gaskets and even chewing gum,
⮚ Used in coated papers, being one of the most cost-effective resins to bind pigmented coatings,
⮚ Used in building applications as a sealing & binding agent behind render as an alternative to
PVA,
⮚ Additionally, used in some rubber cutting boards.
⮚ Used for manufacturing automobile tires.
⮚ Used for making floor tiles, footwear components, cable insulation etc.
Synthesis
Buna N / Nitrile Rubber
Properties
⮚ Possesses excellent resistant to heat, sunlight, oil, acids and salts
⮚ less resistant to alkalis,
⮚ Low tensile strength,
⮚Good heat and abrasion resistance,
Uses
⮚ Used in making fuel tanks, gasoline hoses, conveyor belts, higher altitude aircraft
components etc,
⮚ Used in tank linings, gaskets, printing rollers, adhesives, oil resistant foams, automobile
parts.
⮚ In the form of latex, it is used for impregnating paper, textiles and leathers.
⮚ When vulcanised with carbon black, it is used in petrol tanks and pipes.
Synthesis
Silicone Rubber
Properties
⮚ Possesses excellent resistant to prolonged exposure to sunlight, weathering, boiling water,
oils and dilute acids and alkalies,
⮚ Maintain their rubber characteristics over the temperature range of -100 to 500˚F. Resistant
to air and ozone over this range.
⮚ Remain flexible in the temperature range of 90-250˚C,
⮚ At very high temperature this rubber leaves behind non-conducting silica.
Uses
⮚ Used in making lubricants, paints and protective coatings for fabric finishing and water
proofing,
⮚ Used as a sealing material in search lights and in air crafts engines as adhesive,
⮚ Used for making insulation of iron board of washing machines and electric blankets.
Synthesis
Reclaimed Rubber

⮚Reclaimed rubber is the product obtained from miscellaneous waste rubber articles like
worn out tyres, tubes, gaskets, hoses, foot wear etc., which were heated and treated with
chemicals.
⮚In reclaiming, devulcanisation or regeneration of rubber to its original plastic state takes
place. The devulcanised rubber can be processed, compounded and vulcanised.
⮚ The waste rubber articles are cut into pieces and ground to particles of fine dimensions in a
cracker, which exerts powerful grinding and tearing action.
⮚The ground scrap is fed into fast moving screens which separate the fine particles and divert
the large particles back to the cracker for further grinding.
⮚Finely ground scrap is passed under a magnetic separator for removing ferrous impurities.
⮚ The purified waste powder rubber is then digested in a steam jacketed digester with
agitation blade, with caustic soda solution containing chlorides of Zinc and Calcium at about
200˚C under a pressure of 200 lbs per sq. inch for 8-15 hours. By this process, the fibres are
hydrolysed and rubbers are devulcanised. Sulphur is removed as sodium sulphide and
polysulphide. Reclaiming agent such as petroleum and coal tar and softners are added.
⮚After digestion the charge is forced into a blow down tank where the digested rubber is
washed with spray water. Then it is passed through dewatering press to squeeze out water
and a hot blast of air used to make it dry.
⮚Finally the dried rubber is mixed up with processing, reinforcing agents, small amount of
softners in Banbury mixer and then forced through hot rolls which shape and extrude the
rubber .
Properties
⮚ Much cheaper,
⮚ Required low mixing time,
⮚ Low tensile strength,
⮚ Low abrasion resistance,
⮚ Low thermo-plasticity,
⮚ Better curing properties,
⮚ Easy fabric ability,
⮚ Uniform in composition,
⮚ Better ageing properties,
⮚ Free from scorching problems,
⮚ Do not tent to revert after vulcanisation,
⮚ Processing during extrusion and calendaring takes very little time,
⮚ Heat developed and power consumed during processing and mixing is less than that in
processing and mixing of new rubber.
Uses
⮚Used in making shoes, tyres, tubes, heels, belts, hoses, automobile floor mats, inner tubes,
rubber cement, automotive hard rubber battery containers, solvent cements, water
dispersions, stearing wheels, fender flaps.