Information for the Rubber Industry. Crosslinked Native Oils Factice* Vulcanized Vegetable Oils. Introduction 2

Transcription

1 -KONTAKT 38 Information for the Rubber Industry Crosslinked Native Oils Factice* Vulcanized Vegetable Oils Content Page Introduction 2 1. General information regarding factice 3 2. Structure 4 3. Analysis 4 4. Classification of factice in product groups 5 5. Compound mixing and viscosity 8 6. Processing of compounds containing factice 9 7. Effects of factice on curing characteristics Influence of factice on the physical and chemical properties Use of factice 17 Appendix A. Dosage recommendations 20 B. Recipe examples 21-23

2 -KONTAKT 38 Content Page 1. General information regarding factice 3 2. Structure 4 3. Analysis 4 4. Classification of factice in product groups Sulphur factice Brown sulphur factice Yellow sulphur factice White sulphur factice Sulphur chloride factice Sulphur chloride factice for eraser production Stabilized sulphur chloride factice Factice for special elastomers Peroxide factice 8 5. Compound mixing and viscosity 8 6. Processing of compounds containing factice Injection moulding, transfer moulding, compression moulding Extrusion/Calendering Textile coating Effects of factice on curing characteristics Sulphur vulcanization Peroxide vulcanization Influence of factice on the physical and chemical properties Mechanical properties Hardness Elasticity Compression set Tensile strength Tear strength Abrasion 14 Page 8.2 Resistance Ageing resistance Steam resistance Ozone resistance Weather resistance Oil resistance Other properties Plasticizer absorption Air permeability Dynamic properties Density Surface appearance Discolouration/ Contact staining Fogging Electrical properties Use of factice Types of elastomers Standard elastomers (NR, IR, SBR; BR) NBR CR IIR EPDM Special elastomers Applications Rubber erasers Roller coverings Profiles and hoses Textile coatings Calendered sheets Hard rubber (ebonite) Microcellular rubber products Cable Covering 19 Appendix A. Dosage recommendations 20 B. Examples

3 1. General information regarding factice* The development of crosslinked native oils named factice occurred around the same period as the discovery of the vulcanization process (1839 sulphur vulcanization; 1846 sulphur chloride vulcanization). A factice-like product was already produced in the year 1846 through oxidative treatment of rapeseed oil with nitric acid. The first sulphur factice was produced in 1853 after further developments in processing. The main incentive for the development of factice, was the high price of natural rubber during this period. Oil-sulphur-reactionproducts only cost a fraction of the natural rubber price. The French term caoutchouc factice for rubber substitute gave factice its product name in Based on the ever increasing knowledge of the chemical and physical connections between the structure and properties of factice, one was able to manufacture consistent qualities. These were to be used firstly in natural rubber, and later in synthetic elastomers. Due to the decreasing price of rubber and the increasing technological progress, factice was increasingly used as a processing aid (see Table 1) and is still used today in many areas of the rubber industry. The major raw materials for the production of factice are rapeseed oil and castor oil which are reacted with sulphur, sulphur chloride and hydrogen sulphide. Special forms of factice are reacted with peroxide and diisocyanates. These can, however, only be produced by a few manufacturers. In countries where soya is readily available (e.g. USA), soya oil factices are produced which are generally comparable to rapeseed oil factice. Besides the vegetable oil and sulphur, additional raw materials may be added to different factice qualities which will alter its physical properties, e.g. mineral oils, paraffinic oils, inorganic stabilizers and inorganic fillers etc. To produce the different types of factice, the raw materials and crosslinking agents are mixed and reacted at different temperatures. The reaction time can take up to several days to complete and must follow precisely defined production parameters. The skill of producing factice is the ability to produce a batch conformity even though the raw materials used may differ in quality according to the season. Advantages and effects of factice in rubber compounds Shorter mixing cycles and easier mixing Energy saving due to lower temperatures and shorter mixing cycles Improvement of plasticizer absorption and retention Faster processing, coupled with closer tolerance precision and improved surface appearance Easier degassing and reduction of porosity Reduction of cold flow Improved dimensional stability and better handling of raw compounds Better batch to batch uniformity Reduction of compound density Better surface properties, pleasant surface feeling and better grinding properties Improved dynamic cracking resistance Table 1 *Further descriptions of factice are: Crosslinked Native Oils or Vulcanized Vegetable Oils. In this brochure, the term factice is solely used as a product description as it is commonly used in relevant literature. 3

4 -KONTAKT Structure The crosslinking with use of sulphur, sulphur chloride, hydrogen sulphide or peroxide produces a spherical particle structure of 5 nm (which can be seen through an electron microscope) with a molecular weight of ca This spherical structure explains the influence of factice with regard to the rheological properties of rubber compounds the so called ball bearing effect. The spherical structure also remains during mixing, processing and even after vulcanization. Chemical bonding of the factice molecules to the rubber molecules hardly occurs if at all. The chlorine set free during the production of sulphur chloride factice is bond to the α-carbon atoms adjacent to the crosslinking sites. This crosslinking is of varying levels of bond strength. A part of the bonded chlorine can be eliminated by hydrolysis which produces a vulcanization neutral sulphur chlorine factice.* Figure 1: Molecular structure of factice Source: GAK 19, 1966, 232 Isocyanate factice is produced by crosslinking the hydroxyl groups of native oils building urethane bridges. For peroxide factice carbon bonds are built. Both these types of non-sulphur crosslinks have improved thermal stability. 3. Analysis In the past few years the best criterion for judging the quality of factice became the total sulphur content. By using modern analysis equipment it is possible to control the quality and to steer the production process. To check the degree of polymerisation the acetone extract (AE) or the n-hexane extract values can be examined. These values may differ extremely, depending on the time of measurement (duration of storage). The free sulphur determined in the AE of the factice lies between <0,1 and 3%. The free sulphur can have an effect on the compounds cured with EV systems (low concentrations of sulphur) if large amounts of factice are used. Figure 2: Measurement of the complete sulphur content The amount of inorganic additives can be determined by the ash content. *Sulphur chlorine retards the vulcanization. 4

5 4. Classification of factice in product groups 4.1 Sulphur factice Brown sulphur factice The colour range of brown factice lies between dark and mid brown. DOG offers a range of different types according to individual properties. Product Colour Oil con- Total Sulphur Conforming Use tent (%) content % to BgVV* F 10 brown 0 11,5 14,5 + F 10 soft brown 0 9,5 11,5 + F 14 brown 0 14,5 17,5 + F 17 brown F 25 brown 0 21,5 24,5 + DS soft brown 30 9,5 12,5 K 14 D dark brown FG 140 dark brown PD 14 dark brown 15 12,5 15,5 Dark coloured injection moulded, compression moulded, transfer moulded and free heated articles, linings/coatings, sealings for food applications, bottle rings, roller coverings, hoses Compression moulded, transfer moulded and injection moulded articles based on hard rubber, polishable articles and linings/coatings Compression moulded, transfer moulded and injection moulded articles, cable insulation, microcellular products, roller coverings Dark coloured injection moulded articles, cable insulation, floor coverings, calendered sheets Table Yellow sulphur factice Yellow sulphur factice is similar in molecular structure to brown sulphur factice. The lighter color is obtained by using refined hydrogenated oils. Yellow sulphur factice is used where the light colour required excludes the use of a brown factice. Product Colour Oil con- Total Sulphur Conforming Use tent (%) content % to BgVV* Gloria 17 yellow Light coloured injection moulded Gloria L yellow articles, very soft compression moulded, transfer moulded articles, micro- Hamburg 4 ochre cellular rubber, textile and roller coverings, transparent rubber articles Hamburg M ochre 20 14,5 17,5 Gloria 17 FF yellow Free-flowing version of Gloria 17 Table 3 *Conforming to German food legislation 5

6 -KONTAKT White sulphur factice White sulphur factice is manufactured from special refined rapeseed oil, sulphur and hydrogen sulphide.* It is specifically used in manufacturing transparent, white and pastel coloured rubber compounds. Product Colour Oil con- Total Sulphur Conforming Use tent (%) content % to BgVV* Light coloured injection moulded articles, very soft moulded articles, pastel Corona R 0 13,5 16,5 + microcellular rubber, transparent yellow-white rubber articles,textile and roller coverings Table Sulphur monochloride factice Sulphur monochloride factice for eraser production This factice is produced from rapeseed oil via crosslinking with sulphur chloride and additional basic substances. Product Colour Oil con- Total Sulphur Conforming Use tent (%) content % to BgVV* Nr. 12 white 18 3,5 6,5 Erasers, cold vulcanization Nr. 17 GW white 0 7,5 10,5 + Table Stabilized sulphur chloride factice During the production of these white sulphur chloride factice, the labile-bonded chlorine has been removed through hydrolysis after treatment with basic inorganic substances. Stabilized sulphur chloride factice gives an excellent dimensional stability to the rubber compounds, as well as an exceptionally low influence on the compression set. Product Colour Oil con- Total Sulphur Conforming Use tent (%) content % to BgVV* Injection moulded and soft form Hansa O ivory articles with an excellent dimensional stability, textile covering Hansa F ivory 0 5,5 8,5 + Free-flowing version of Hansa O Table 6 *Mainly mono- or disulphidic crosslinking 6

7 4.3 Factice for special elastomers Special elastomers often require the use of oil resistant factice made from castor oil. Dependent upon the colour requirements of the compound, Corona Q, NQ or RQ 18 can be used. Should oil resistance in CR compounds be of minor importance then types NP 17 and NC 12 may also be used. Produkt Colour Oil con- Total Sulphur Conforming Use tent (%) content % to BgVV* Corona Q pastel yellow-white NQ light brown RQ 18 brown NC 12 ivory 0 6,5 9,5 NP 17 brown 0 11,5 14,5 Light coloured compression moulded, transfer moulded and injection moulded articles made of NBR/CR, roller coverings, calendered sheets, printing sheets, articles with swell resistance against petrol and mineral oil (fuel hoses) Coloured compression moulded, transfer moulded and injection moulded articles made of NBR/ CR, roller coverings, calendered sheets, printing sheets, articles with swell resistance against petrol and mineral oil (fuel hoses) Dark coloured compression moulded, transfer moulded and injection moulded articles made of NBR/CR, roller coverings, calendered sheets, printing sheets, articles with swell resistance against petrol and mineral oil (fuel hoses) Special factice for compression moulded, transfer moulded and injection moulded articles made of CR Special factice for dark coloured compression moulded, transfer moulded and injection moulded articles made of CR Table 7 7

8 -KONTAKT Peroxide factice By crosslinking modified castor oil with peroxides, DOG produces a chlorine free white factice: WP This is an ideal choice where extremely high vulcanization temperatures are required, for example in LCM and UHF-processes and articles requiring long term heat resistance. In comparison to sulphur and sulphur chloride factice, WP offers the best compression set values. Product Colour Oil con- Total Sulphur Conforming Use tent (%) content % to BgVV* Profiles and compression moulded, WP white 0 0 transfer moulded articles, especially for peroxide cure, erasers Table 8 5. Compound mixing and viscosity Factice can be rapidly and uniformly dispersed into the rubber compound using all standard mixing methods. In most cases it is recommended that factice is added to the compound at the beginning of the mixing process. The presence of factice facilitates the mixing and improves the dispersion of fillers and plasticizers. Compounds with substantial amounts of plasticizer are easily mixed and handled, as factice has an excellent absorption and retention capacity for plasticizers. Generally due to the better absorption of fillers and plasticizers, a noticeable reduction in the mixing time can be achieved leading to a reduction in the use of energy. As factice also helps decrease the inner friction of the compound (ball-bearing effect), a distinct reduction in the mixing temperature is obtained. This can be seen in the following study. Recipe phr phr SBR NR SMR CV CaCO SiO Carbon black for colouring 1 1 ZnO 5 5 Stearic acid 1 1 F 10 (factice) 20 Release temperature 125 C 105 C Internal mixer 35 l, mixing time: 5 min. Table 9 Due to the reduced process temperature obtained by using factice, a certain protection can be archieved against premature onset of cure (scorch). Compounds containing factice are more easily sheeted off the mill, and show less shrinkage than those not containing factice. 8

9 6. Processing of compounds containing factice Improvement of extrusion rate Improvement of dimensional stability of uncured compounds Improvement of calendering properties Better textile bonding properties Advantages of the use of factice Smoother surface Reduction of density Velvety surface Improved building properties Table Injection moulding, transfer moulding, compression moulding By adding different factice grades, the flow and injection behaviour of compounds can be influenced. This can steer the working process of transfer moulding, compression moulding and injection moulding. For example, due to shorter injection times, the moulds can be filled more rapidly, the production and heating times can be shortened and the amount of defects is reduced. Factice enables shorter cycle times, reduces air entrapment and improves the mould release. Factice provides better dimensional stability of uncured compounds and premoulds, and counteracts the effect of cold flow during storage (e.g. compounds based on IIR or CSM). 6.2 Extrusion / Calendering The positive effect of factice on the flow of the compound can be seen by the increased extrusion rate, reduced die swell, and a uniform appearance even on complicated thin lipped profiles. Another advantage of factice is easier degassing which enables the manufacture of non-porousarticles in open cure. Extrusion characteristics according to dosage Test parameters Laboratory extruder, 20 mm screw Round die, 3 mm Mini-Garvey die area 7,06 mm 2 Mixture: SBR / NR (compare Table 9) Extrusion Diagramm ASTM Extrusion speed Torque Swelling % phr F 10 Surface quality according to ASTM D 2230 Improvement Figure 3 9

10 -KONTAKT 38 The calendering properties of rubber compounds are influenced in a similar manner through factice as with extrusion. The mechanical requirements for both compounds are similar. Factice enables the compound to deform without tension strain when passed through the calender nip/extruder head, and to retain its form. Compounds containing factice calender with remarkable smoothness and uniformity. The swelling after leaving the roll nip is reduced, as well as the longitude shrinking of the sheet. As a result, the so called calender effect is reduced in compounds containing factice, in comparison to those without. Additionally calendered sheets containing factice, present a pleasant surface texture after vulcanization as is required by many applications. The compounds are also less temperature sensitive, which enables an easier handling during the calendering. NR compound with 50 phr factice, without further additives. Comparison of dimensional stability improvement Dimensiona stability index % 1: Hansa O 2: Corona R 3: F 10 4: F 14 5: F 17 6: DS soft Figure 4 Factice with plasticizer content show a reduced influence on dimensional stability of compounds, whereas Hansa O (without plasticizer) provides the best dimensional stability. 6.3 Textile coating The favourable influence in rubber solution applications has long been known. Compounds containing factice need less solvents to adjust the viscosity and are more consistent than those without. There is also a reduced tendency towards strike through and the specified coat thickness is reached with a lesser number of coating cycles. These factice containing compounds are less likely to thread and are easier to spread. 10

11 7. Effects of factice on curing characteristics Compounds containing factice can be cured in all conventional and modern vulcanization processes including those using high temperatures. These compounds support the standard vulcanization cycles even at temperatures above 200 C, without decomposition. Our factice WP is especially suited for these high temperatures. Polar factice, such as those based on castor oil, can enhance the temperature effect during microwave cure (UHF), and thereby accelerate the curing process. 7.1 Sulphur vulcanization Factice tends to have a slight accelerating effect upon the scorch of rubber compounds Scorch time (t 10 ) EPDM-Compound 836 E* Control 5 phr 10 phr 20 phr Figure 5 The influence on the cure time t 90 may differ, dependent upon the factice type and dosage. Figure 6 min Curing time (t 90 ) Compound 836 E* Control 5 phr 10 phr 20 phr min Keltan Durex O 120 Sunpar EPDM base compound (S-System) 836 E Stearic acid 1 ZnO 5 Deovulc BG Sulphur 1,5 Table 11 *The graphics were constructed using mean values which were obtained in examinations within the temperature range of C. 11

12 -KONTAKT Peroxide Vulcanization For peroxide vulcanization, it is preferable to use factice of the same crosslinking structure (WP) as it hardly influences the vulcanization. Scorch time (t 10 ) Compound 835 E* Control 5 phr 10 phr 20 phr Figure 7 The influence on curing time (t 90 ) may differ dependand upon factice grade. Curing time (t 90 ) Compound 835 E* min min Control 5 phr 10 phr 20 phr Figure 8 Keltan Durex O 120 Sunpar Table 12 EPDM base compound (Peroxid) 835 E Stearic acid 1 ZnO 5 Perkadox 14/40 8 Taic 70%ig 2 *The graphics were constructed using mean values which were obtained in examinations within the temperature range of C. 12

13 8. Influences of factice on the physical and chemical properties 8.1 Mechanical properties Hardness Through the addition of factice, very soft compounds can be produced with high plasticizer loadings. The plasticizer binding capacity of factice enables a reduction in the region of 20 Shore A without the plasticizer migrating to the surface. Factice can also be used to produce hard compounds (80 Shore A) as factice containing compounds enable higher dosages of filler, whilst keeping the favourable processing properties. For the production of Ebonite, F 25 is recommended Elasticity (rebound resilience) By adding factice to elastomers with low resilience, a substantial increase in elasticity can be obtained. In compounds characterized by high rebound resilience there is no change in elasticity when factice is added. With increased filler levels factice can be used to maintain the required level of elasticity Compression Set The influence of factice on the compression set is dependand upon the grade and dosage. Generally the compression set will be increased by adding factice. The least influence is obtained with sulphur chloride factice (Hansa O) and peroxide factice (WP). Compression Set 24 h/100 C (Sulphur vulcanization)* Control 5 phr 10 phr 20 phr % Figure 9 *The graphics were constructed using mean values which were obtained in examinations within the temperature range of C. 13

14 -KONTAKT 38 Compression Set 24 h/100 C (Peroxide vulcanization)* Control 5 phr 10 phr 20 phr % Figure 10 To obtain an ideal compression set in peroxide vulcanized compounds, the use of peroxide factice (WP) is recommended Tensile strength In most cases factice will decrease the tensile strength of rubber compounds. In compounds with large filler content, small amounts of factice can increase the tensile strength as a result of its dispersion effect Tear strength The tear strength of compounds without fillers will be reduced by the addition of factice. This is explained by the fact that factice is not a reinforcing filler, nor does it generate a lower state of cure. The required tear strength can be obtained by modifying the filler grades and dosage. In high or medium durometer compounds, an increase filler loading is required to compensate the decreased hardness induced by factice. This will also reduce the negative influence on tear strength. An exception, however, is IIR, where factice leads to a substantial increase in tear strength Abrasion Rubber compounds containing factice show a higher abrasion than those without. For this reason, factice is not used in products requiring high wear resistance such as tyre treads. When working with relatively small dosages of factice as a processing aid, a detrimental effect on abrasion is hardly noted. On the other hand high factice loadings increase the abrasion which is favourable for the production of rubber erasers. These properties of factice, allow an excellent grinding of finished products i.e. roller covers. *The graphics were constructed using mean values which were obtained in examinations within the temperature range of C. 14

15 8.2 Resistance Ageing resistance Factice generally does not affect the static heat- and long term ageing properties of rubber compounds. An advantageous effect can be obtained in dynamic articles (see 8.3.3) Steam resistance Factice does not suffer under the conditions of open steam cure. The autoclave vulcanization of compounds containing factice is a long established practice in the rubber industry. Also steam sterilisation of products containing factice does not effect them negatively. The hydrolysis of the ester crosslinks only takes effect when exposed to high temperatures for long periods of time Ozone resistance The ozone resistance of compounds based on NR, SBR, NBR or IIR will normally not be affected by the addition of factice. This is understandable, as the chemical structure of factice does not influence ozone attack on the rubber polymer. In diene rubber compounds the addition of factice necessitates an increase of waxes in the recipe. This is due to the fact that factice absorbs the wax, decreasing the amount of wax that migrates to the surface. For this reason it may be necessary to increase the dosage of antiozonant wax. In CR compounds, factice improves the static ozone resistance. This is explained by the positive influence of factice on the modulus Weather resistance The information regarding ozone resistance (see 8.2.3) is also relevant for the ageing properties of compounds under tension. The weathering of light coloured rubber compounds which are not subject to tension strain, is known to lead to surface effects such as crazing or frosting (frosting is not to be confused with surface bloom of powdered compound ingredients). In all DOG studies, no positive or negative influence on the afore mentioned effects could be ascertained Oil resistance In NBR compounds, the addition of rape seed oil factice has lowered the oil resistance. Castor oil factices (Corona Q, NQ, RQ 18) affect the oil swell characteristics to a different degree, this is dependent upon the ACN content (see Table 13) In CR compounds, the oil resistance properties can even be improved by adding castor oil factice. 15

16 -KONTAKT Other properties Plasticizer absorption Rubber compounds containing factice enable the incorporation of larger amounts of plasticizer and also prevent its migration to the surface. Factice has proved to be effective when mixing naphthenic plasticizers in CR. This also applies when large amounts of ester plasticizer are to be added to NBR e.g. soft roller coverings Air permeability When used in concentrations of max. 20 phr, factice does not affect the air permeability characteristics of the rubber compound even in IIR Dynamic properties Factice frequently shows a favourable effect on the dynamic flexcracking resistance (as evaluated in the DeMattia test). Factice tends to loosen the supermolecular structure of elastomers. This is shown by a decrease in modulus. These benefits have traditionally been used in the manufacture of shoe uppers. The incorporation of factice has also improved the wet and dry grip Density As factice has a relatively low density, the incorporation in the rubber compound also reflects this redution Surface appearance Free heated articles which are produced with factice show a distinguished velvety surface touch, in contrast to the greasy, glossy surface of many factice-free compounds. The factice particles distribute uniformly throughout the rubber matrix and generate a microscopically fine, ondulated surface which explains the pleasant, textile-like feel. Steam cured compounds using factice, rarely show condensation spots on their dull velvet like surface. A further advantage of their surface structure is, that they offer a lower coefficient friction towards glass and painted metals. This is an advantage when installing rubber profiles and replacing glass windows and panels Discolouration/Contact Staining The rubber industry differentiates between discolouration and contact staining. In both cases, factice does not have any negative influence what so ever Fogging Due to the better plasticizer retention, it is assumed that factice has an advantageous affect against fogging. 16

17 8.3.8 Electrical properties These properties in rubber compounds are hardly affected by factice. In cured articles with resistance levels within the insulation range (above 10 9 Ohm x cm) the presence of factice will decrease the results at best by a factor of ten i.e. the antistatic area is not reached. The electrical conductivity of compounds containing factice does not differ strongly from those without when submerged in water. 9. Use of factice 9.1 Types of elastomers Standard elastomers (NR, IR, SBR, BR) In the production of many extruded, calendered and moulded articles factice is an important indispensable ingredient in the compound. The reduction of the compound viscosity, the improvement of the injection flow, the increase in dimensional stability and the improved plasticizer absorption and retention are only a few of the reasons for using factice. (see dosage recommendations) NBR NBR is often used for the production of oil resistant rubber goods. Its swell characteristics are hardly affected by the factice grades Corona Q, NQ and RQ 18. However the influence of factice changes with changing levels of ACN. ACN-level Effect of castor oil factice 18-28% ACN-NBR Improvement of oil resistance 33% ACN-NBR neutral 38-51% ACN-NBR Reduction of oil resistance Table 13 Factice WP is recommended for the peroxide vulcanization of NBR and also permits low compression set values CR CR is often used, where the oil resistance is of minor or middle importance. CR offers excellent weathering and ageing properties. Naturally, castor oil factices and peroxide factices can be used to improve the swell characteristics of CR. The Factice NC 12 (ivory) and NP 17 (brown) are especially suitable for this rubber type, and increase the injection flow considerably. 17

18 -KONTAKT IIR Because of its low gas permeability, IIR is often used for the production of inner tubes and liners as well as other extruded products. The affinity to cold flow, due to its thermoplastic character, can be reduced with factice. The compounds containing factice, can be extruded faster, have a better dimensional stability and can be welded better which is of importance for bicycle and automobile inner tubes. Furthermore, factice improves the resilient properties and the tear strength. This effect can clearly be seen in dark as well as in light coloured compounds, even with high factice dosages. The improved tear strength is a further reason why IIR is used in the production of bicycle and automobile inner tubes EPDM EPDM is well known for the production of high loaded compounds. By adding factice, the compounds are much easier to sheet off, easier to handle and tend not to cold flow. The tendency of highly plasticized EPDM compounds to produce porous extrusions is minimized by the de-gassing capability of factice containing compounds. In many cases, even small amounts of factice enable the production of non-porous extrusions. This is of particular interest for compounds processed in less pressure curing units, such as LCM and UHF, where up to 20 phr factice are often used. In microwave curing, some polar factices can even contribute towards a faster heat rise under UHF waves. Factice has also established its value in respect of improving the welding characteristics of EPDM, and for the manufacture of flexible and supple sheeting. Factice WP is especially suitable for peroxide cured EPDM compounds, giving the advantage of a low compression set Special elastomers Factice can be advantageous in special elastomers such as CSM, CO, EAM, PU, ECO, ACM if added in small dosages. The advantageous properties of factice i.e. plasticizer retention, structure building and degassing, can also be used in special elastomers. Sulphur and chlorine free factice such as our WP, is often used in special elastomers. One should, however, check in advance that the quality of compounds do not suffer when considering the advantages and processing properties of factice Applications Rubber erasers In eraser compounds, factice represents the largest ingredient with up to 400 phr. In this case, rubber is only present as binder for the factice whose abradability is intentionally exploited. Especially suitable are non-stabilised sulphur chloride factice. Chlorine and sulphur free peroxide factices (WP) are also used for the production of erasers Roller coverings Roller covers containing factice accept more readily the printing ink and give a sharper contrast when printing. Also for the production of extremely soft qualities (coverings with 20 shore A) the only practical solution is to add up to 100 phr factice to obtain an ideal compound. The good plasticizer retention and the good building up properties of compounds containing factice are also an important factor. A better handling and a distinct improvement of the grinding capabilities can be obtained by adding factice. 18

19 9.2.3 Profiles and hoses As with all extruded articles, the dimensional stability, form stability, output and surface quality are of great importance. The use of factice helps to achieve these attributes and enables a optimization of the production process. Factice enables an easier handling of the compound and provides better grinding qualities. Factice improves the welding properties of the components in coextrusion processes Textile coatings The incorporation of factice in textile coating compounds generates primarily a pleasant velvet-like surface wich is similar to a textile surface. In the production of printing cloth the effects are the same as with roller covering. A further advantage is, that less spreading steps are required to obtain the desired coating thickness Calendered sheets When producing calendered sheets, the advantage of factice is, that the compound does not stick to the roller. Also the air entrapment is reduced, the form stability is safeguarded and a smooth surface is obtained Ebonite To reduce the exotherme reaction in ebonite vulcanization, highly sulphured factice (F 25) is added to the compound. Ebonite is still able to be polished, when a dosage of up to 25 phr is added Microcellular rubber products In microcellular rubber products factice improves the dispersion of the compound ingredients and thus helps to obtain a uniform pore distribution. Additionally, the handling properties and the dimensional stability are improved. Experience has shown that the grades Gloria and Hamburg are especially suitable for microcellular rubber Cable covering By incorporating peroxide factice (WP) in the compound, the form stability and the extrusion speed of the cable can be increased. This can be achieved, without having negative effects on its electrical properties. 19

20 -KONTAKT 38 Appendix A. Dosage recomendations Factice can be added in various dosages (5-400 phr). Because of the many different applications of factice, the following list can only be seen as general guideline. Our technical customer service department will gladly give you further information. Articles Dosage (phr) DOG factice grades Extruded articles General purpose brown/yellow/white sulphur factice, Hansa O, Hansa F rubbers (NR, IR, SBR) ACM 5-10 WP CR Corona Q, NQ, RQ 18, NC 12, NP 17, WP CSM 10 brown/yellow sulphur factice, Hansa O, Hansa F ECO 5-10 WP EPDM brown/yellow/white sulphur factice, Hansa O, Hansa F IIR brown/yellow/white sulphur factice, Hansa O, Hansa F NBR Corona Q, NQ, RQ 18, NC 12, NP 17, WP Peroxide cured 5-15 WP compounds Calendered articles General purpose brown/yellow/white sulphur factice, Hansa O, Hansa F rubbers (NR, IR, SBR) CR Corona Q, NQ, RQ 18, NC 12, NP 17, WP CSM 10 brown/yellow/white sulphur factice, Hansa O, Hansa F, Corona Q, NQ, RQ 18, NC 12, NP 17, WP EPDM brown/yellow/white sulphur factice, Hansa O, Hansa F IIR brown/yellow/white sulphur factice, Hansa O, Hansa F NBR Corona Q, NQ, RQ 18, NC 12, NP 17, WP Moulded articles, Compression-, Injection- und Transfer-moulding General purpose brown/yellow/white sulphur factice, Hansa O, Hansa F rubbers (NR, IR, SBR) ACM 5-10 WP CR Corona Q, NQ, RQ 18, NC 12, NP 17, WP CSM 5-10 brown/yellow/white sulphur factice, Hansa O, Hansa F, Corona Q, NQ, RQ 18, NC 12, NP 17 ECO 5-10 WP NBR Corona Q, NQ, RQ 18, NC 12, NP 17, WP Peroxide crosslinked 5-10 WP compounds Roller coverings Shore A 10 } Recommendation depends on rubber typ, Shore A please contact our technical advisors under 50 Shore A brown/yellow/white sulphur factice, Hansa O, Hansa F, under 20 Shore A Corona Q, NQ, RQ 18, NC 12, NP 17 Erasers Nr. 12, Nr. 17 GW Textile coatings brown/yellow/white sulphur factice, Hansa O, Hansa F, Corona Q, NQ, RQ 18, NC 12, NP 17 Microcellular products brown/yellow/white sulphur factice Ebonite 5-25 F 25 Transparent rubber articles Corona R, WP, Corona Q Table 14 20

21 B. Recipe examples Influence of various factice grades (dosage 15 phr) on NR-compounds Recipe Factice- Compression Set Tensile Elongation Hard- Regrade (%) strength at break ness bound 22h/70 C 70h/20 C (MPa) (%) (Shore A) (%) Smoked Sheets 100,0 Carbon black N ,0 ZnO RS 5,0 Stearic acid 2,0 IPPD 2,0 Controzon W 3,0 Sulphur 2,2 MBTS 1,1 TMTD 0,15 Factice 15,0 (Press cure, 20 min. at 145 C) Corona R , Gloria , F , F , F , DS soft , K 14 D , PD , Hansa O , Control , Table 15 Influence of various factice grades (dosage 15 phr) on NBR-compounds Recipe Factice- Compression Set Tensile Elongation Hard- Regrade (%) strength at break ness bound 22h/70 C 70h/20 C (MPa) (%) (Shore A) (%) NBR (33% ACN) 100,0 Carbon black N ,0 Stearic acid 1,0 ODPA 1,0 Sulphur 1,8 CBS 1,1 TMTM 0,1 Factice 15,0 (Press cure, 15 min. at 150 C) Hansa O , NQ , RQ , WP , Control , Table 16 21

22 -KONTAKT 38 Influence of various factice grades (dosage 15 phr) on OE-SBR-compounds Recipe Factice- Compression Set Tensile Elongation Hard- Regrade (%) strength at break ness bound 22h/70 C 70h/20 C (MPa) (%) (Shore A) (%) SBR ,5 Carbon black N ,0 Chalk 20,0 Vaseline 10,0 ODPA 2,0 Controzon W 3,0 ZnO RS 5,0 Stearic acid 1,5 Sulphur 2,2 MBTS 1,0 DPG 0,2 Factice 15,0 (Press cure 30 min. at 158 C) Corona R , Gloria , F , F , F , DS soft , K 14 D , PD , Hansa O , Control , Table 17 Influence of various factice grades (dosage 15 phr) on IIR-compounds Recipe Factice- Compression Set Tensile Elongation Hard- Regrade (%) strength at break ness bound 22h/70 C 70h/20 C (MPa) (%) (Shore A) (%) IIR 100,0 Carbon black N ,0 Paraffinic oil 10,0 Stearic acid 1,0 ZnO RS 5,0 Sulphur 1,5 MBT 1,3 TMTD 0,7 ZDEC 1,0 Factice 15,0 (Press cure 30 min. at 151 C) Corona R , Gloria , DS soft , K 14 D , WP , Control , Table 18 22

23 Influence of various factice grades (dosage 15 phr) on CR-compounds Recipe Factice- Compression Set Tensile Elongation Hard- Regrade (%) strength at break ness bound 22h/70 C 70h/20 C (MPa) (%) (Shore A) (%) CR (mercaptan type) 100,0 Carbon black N ,0 Carbon black N ,0 Naphthenic oil 14,0 Stearic acid 0,5 ODPA 2,0 Controzon W 2,0 MgO light 4,0 ZnO RS 5,0 ETU 0,5 Factice 15,0 (Press cure, 15 min. at 153 C) Hansa O , NC , NP , NQ , RQ , WP , Control , Table 19 Influence of various factice grades (dosage 15 phr) on EPDM-compounds Recipe Factice- Compression Set Tensile Elongation Hard- Regrade (%) strength at break ness bound 22h/70 C (MPa) (%) (Shore A) (%) EPDM 4% EN 100,0 N 774 Carbon black 120,0 Paraffinic oil 50,0 ZnO 5,0 Stearic acid 2,0 Deovulc EG 3 4,0 Sulphur 2,0 Factice 15,0 (Press cure, 20 min. at 165 C) Corona R 52 10, Gloria , DS soft 44 9, K 14 D 38 9, WP 27 8, Control 40 12, Table 20 Impressum: Editor: DOG DEUTSCHE OELFABRIK Gesellschaft für chemische Erzeugnisse mbh & Co KG D Hamburg, Ellerholzdamm 50 Tel. +49 (0)40/ Fax +49 (0)40/ info@dog-chemie.de Internet: Authors: Henry Ahrens, Dr. Bernd Bornemann John Chapman, Joachim Diederichsen Manfred Heide, Wolfgang Zech Production: EHRENBERG WERBUNG Tel. +49 (0)40/ , Fax +49 (0)40/ Use of text and pictures even in extracts is subject to approval of the editor and is illegal to copyright. This also applies to copies, translations, micro recording, saving on data carrier and/or commercial use of addresses and names especially sales to third parties. 23

24 Europe Asia America Africa Australia Austria Belgium Bulgaria Croatia Czechoslovakia Denmark Finland France Germany Great Britain Greece Hungary Ireland Italy Luxembourg Norway Poland Portugal Romania Slovakia Slovenia Spain Sweden Switzerland The Netherlands Turkey Yugoslavia China (PRC) India Indonesia Iran Israel Japan Lebanon Malaysia Pakistan Philippines Singapore South Korea Sri Lanka Taiwan (ROC) Thailand United Arab Emirates Vietnam Argentina Brasil Chile Canada Colombia Mexico Peru USA Venezuela South Africa Australia Zimbabwe New Zealand Any technical consultation provided by us merely constitutes a guideline without any committal even with regard to any third party s rights and will not dispense from the clients examination of the products supplied by us. Processing operations, application and use of our products will be the client s exclusive responsibility. We guarantee the faultless quality of our goods, as defined in our general terms of sale and delivery. DOG DEUTSCHE OELFABRIK Gesellschaft für chemische Erzeugnisse mbh & Co KG Ellerholzdamm 50 D Hamburg Postbox D Hamburg Tel. +49(0)40/ Fax +49(0)40/ info@dog-chemie.de Internet: