Sulfur Free Crosslinking of EPDM Composites via Silane Grafting and Silica Incorporation.

This study aims at evaluating and developing an environmental-friendly and sulfur-free cured ethylene propylene diene monomer (EPDM) composites. Silane grafted EPDM (SiEPDM) composites incorporated with silica is prepared via a solvent-free, one-step reactive mixing process. The silane grafting and silica filler bonding are characterized using Fourier transform infrared spectroscopy and X-ray photoelectron spectroscopy. The mechanical properties of the developed composites are examined. The fracture morphology is observed using an environmental scanning electron microscopy. The rheology and thermomechanical properties are evaluated by using a rotational rheometer and dynamic mechanical analyzer. Notably, a robust bonding between silica and the grafted silane is established, yielding a crosslinking network within the composite structure. This phenomenon is substantiated by the observed gel efficiency and rheology behavior. Consequently, a pronounced augmentation of up to 75% in tensile strength and 29% in tear strength are observed in the optimized SiEPDM-silica composites, distinguishing them from their EPDM-silica counterparts. The introduction of paraffin oil contributes to enhanced processability; however, it is concomitant with a reduction in gel efficiency and associated mechanical properties. Furthermore, subsequent UV weathering test unveils that the SiEPDM-silica composites exhibit the highest levels of residual tensile strength and modulus, indicative of their exceptional UV stability.

Experimental and Finite Element Simulation of Polyolefin Elastomer Foams Using Real 3D Structures: Effect of Foaming Agent Content.

In this study, polyolefin elastomer (POE) foams were prepared without any curing agent using a single-step foaming technique. The effect of azodicarbonamide (ADC) content as a chemical foaming agent on the foams' morphology and mechanical properties was studied using scanning electron microscopy (SEM), mechanical properties (tension and compression) and hardness. The results showed that increasing the ADC content from 2 to 3, 4 and 5 phr (parts per hundred rubber) decreased the foam density from 0.75 to 0.71, 0.65 and 0.61 g/cm3, respectively. The morphological analysis revealed that increasing the ADC content from 2 to 4 phr produced smaller cell sizes from 153 to 109 µm (29% lower), but a higher cell density from 103 to 591 cells/mm3 (470% higher). However, using 5 phr of ADC led to a larger cell size (148 µm) and lower cell density (483 cells/mm3) due to cell coalescence. The tensile modulus, strength at break, elongation and hardness properties continuously decreased by 28%, 21%, 16% and 14%, respectively, with increasing ADC content (2 to 5 phr). On the other hand, the compressive properties, including elastic modulus and compressive strength, increased by 20% and 64%, respectively, with increasing ADC content (2 to 5 phr). The tensile and compression tests revealed that the former is more dependent on foam density (foaming ratio), while the latter is mainly controlled by the cellular structure (cell size, cell density and internal gas pressure). In addition, 2D SEM images were used to simulate the foams' real 3D structure, which was used in finite element methods (FEM) to simulate the stress-strain behavior of the samples at two levels: micro-scale and macro-scale. Finally, the FEM results were compared to the experimental data. Based on the information obtained, a good agreement between the macro-scale stress-strain behavior generated by the FEM simulations and experimental data was obtained. While the FEM results showed that the sample with 3 phr of ADC had the lowest micro-scale stress, the sample with 5 phr had the highest micro-scale stress due to smaller and larger cell sizes, respectively.

Physical Hybrid of Nanographene/Carbon Nanotubes as Reinforcing Agents of NR-Based Rubber Foam.

Natural rubber (NR) foams reinforced by a physical hybrid of nanographene/carbon nanotubes were fabricated using a two-roll mill and compression molding process. The effects of nanographene (GNS) and carbon nanotubes (CNT) were investigated on the curing behavior, foam morphology, and mechanical and thermal properties of the NR nanocomposite foams. Microscope investigations showed that the GNS/CNT hybrid fillers acted as nucleation agents and increased the cell density and decreased the cell size and wall thickness. Simultaneously, the cell size distribution became narrower, containing more uniform multiple closed-cell pores. The rheometric results showed that the GNS/CNT hybrids accelerated the curing process and decreased the scorch time from 6.81 to 5.08 min and the curing time from 14.3 to 11.12 min. Other results showed that the GNS/CNT hybrid improved the foam's curing behavior. The degradation temperature of the nanocomposites at 5 wt.% and 50 wt.% weight loss increased from 407 °C to 414 °C and from 339 °C to 346 °C, respectively, and the residual ash increased from 5.7 wt.% to 12.23 wt.% with increasing hybrid nanofiller content. As the amount of the GNS/CNT hybrids increased in the rubber matrix, the modulus also increased, and the Tg increased slightly from -45.77 °C to -38.69 °C. The mechanical properties of the NR nanocomposite foams, including the hardness, resilience, and compression, were also improved by incorporating GNS/CNT hybrid fillers. Overall, the incorporation of the nano hybrid fillers elevated the desirable properties of the rubber foam.

Chemistry, Processing, Properties, and Applications of Rubber Foams.

With the ever-increasing development in science and technology, as well as social awareness, more requirements are imposed on the production and property of all materials, especially polymeric foams. In particular, rubber foams, compared to thermoplastic foams in general, have higher flexibility, resistance to abrasion, energy absorption capabilities, strength-to-weight ratio and tensile strength leading to their widespread use in several applications such as thermal insulation, energy absorption, pressure sensors, absorbents, etc. To control the rubber foams microstructure leading to excellent physical and mechanical properties, two types of parameters play important roles. The first category is related to formulation including the rubber (type and grade), as well as the type and content of accelerators, fillers, and foaming agents. The second category is associated to processing parameters such as the processing method (injection, extrusion, compression, etc.), as well as different conditions related to foaming (temperature, pressure and number of stage) and curing (temperature, time and precuring time). This review presents the different parameters involved and discusses their effect on the morphological, physical, and mechanical properties of rubber foams. Although several studies have been published on rubber foams, very few papers reviewed the subject and compared the results available. In this review, the most recent works on rubber foams have been collected to provide a general overview on different types of rubber foams from their preparation to their final application. Detailed information on formulation, curing and foaming chemistry, production methods, morphology, properties, and applications is presented and discussed.