Marcel Dekker, Inc. New York • Basel Rubber Compounding Chemistry and Applications edited by Brendan Rodgers The Goodyear Tire & Rubber Company Akron, Ohio DK1284_FM 6/21/04 1:44 PM Page i Although great care has been taken to provide accurate and current information, neither the author(s) nor the publisher, nor anyone else associated with this publica- tion, shall be liable for any loss, damage, or liability directly or indirectly caused or alleged to be caused by this book. The material contained herein is not intended to provide specific advice or recommendations for any specific situation. Trademark notice: Product or corporate names may be trademarks or registered trade- marks and are used only for identification and explanation without intent to infringe. Library of Congress Cataloging-in-Publication Data A catalog record for this book is available from the Library of Congress. ISBN: 0-8247-4871-9 This book is printed on acid-free paper. Headquarters Marcel Dekker, Inc., 270 Madison Avenue, New York, NY 10016, U.S.A. tel: 212-696-9000; fax: 212-685-4540 Distribution and Customer Service Marcel Dekker, Inc., Cimarron Road, Monticello, New York 12701, U.S.A. tel: 800-228-1160; fax: 845-796-1772 Eastern Hemisphere Distribution Marcel Dekker AG, Hutgasse 4, Postfach 812, CH-4001 Basel, Switzerland tel: 41-61-260-6300; fax: 41-61-260-6333 World Wide Web http://www.dekker.com The publisher offers discounts on this book when ordered in bulk quantities. For more information, write to Special Sales/Professional Marketing at the headquarters address above. Copyright nnnnnn 2004 by Marcel Dekker, Inc. All Rights Reserved. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming, and recording, or by any information storage and retrieval system, without permission in writing from the publisher. Current printing (last digit): 10987654321 PRINTED IN THE UNITED STATES OF AMERICA 4871-9_Rodgers_Prelims_R2_052404 MD: RODGERS, JOB: 03286, PAGE: ii Copyright © 2004 by Taylor & Francis Preface Rubber compounding includes the science of elastomer chemistry and the modification of elastomers and elastomer blends by addition of other materials to meet a set of required mechanical properties. It is therefore among the most complex disciplines in that the materials scientist requires a thorough understanding of materials physics, organic and polymer chemistry, inorganic chemistry, thermodynamics, and reaction kinetics. The rubber industry has changed over the last few years. For example, tires have evolved from bias to tubeless radial constructions, and now ultralow-profile products are emerging. Service lives of tires and of industrial products such as automobile engine hoses have dramatically improved. None of these innovations would have been possible without an emphasis on the understanding of the chemistry of raw materials and compounds. Examples of advances in materials technologies over recent years include 1. Commercialization of functionalized and coupled, solution-poly- merized polymers 2. Thermoplastic elastomers 3. Development of silica tread compound for high-performance tires 4. Hybrid filler systems and nanocomposite technologies 5. Reversion-resistant vulcanization systems 6. Halobutyl polymers, which were the foundation for the develop- ment of the tubeless radial tire 7. A new emphasis on recycling and renewable sources for raw materials 4871-9_Rodgers_Preface_R2_052404 MD: RODGERS, JOB: 03286, PAGE: iii Copyright © 2004 by Taylor & Francis To elaborate on the philosophy behind this book, we want to emphasize the chemistry of the materials used in building a compound formulation for a tire or engineered product. Although subjects are not presented at an introductory level, this is not an advanced treatise. Rather, it is intended as a tool for the industrial compounder, teacher, or other academic scientist, to provide basic information on materials used in the rubber industry. It also addresses a gap in the body of literature available to the chemist in industry and academia. One chapter describes the application of materials technolo- gies in products such as hoses, conveyor belts, and tires. As Fred Barlow said in his book, Rubber Compounding, Second Edition (Dekker, 1993), no comprehensive review of a subject such as this could be written by one individual. The compilation of this work thus depended on many contributors, and I want to express my thanks to the authors who participated in the project. All are recognized authorities in their field, and this is reflected in the quality of their contributions. I also wish to express many thanks to both Joseph Gingo, Senior Vice President, and Carl Payntor at The Goodyear Tire & Rubber Company for their support, to the staff at Marcel Dekker, Inc., Rita Lazazzaro and Lila Harris for their patience, and most important to my wife, Elizabeth, for her encouragement. Brendan Rodgers 4871-9_Rodgers_Preface_R2_052404 MD: RODGERS, JOB: 03286, PAGE: iv Copyright © 2004 by Taylor & Francis Contents Preface Contributors 1.NaturalRubberandRecycledMaterials William Klingensmith and Brendan Rodgers 2.General-PurposeElastomers Howard Colvin 3.Special-PurposeElastomers Sudhin Datta 4.ButylRubbers Walter H. Waddell and Andy H. Tsou 5.ThermoplasticElastomers:FundamentalsandApplications Tonson Abraham and Colleen McMahan 6.CarbonBlack Wesley A. Wampler, Thomas F. Carlson, and William R. Jones 4871-9_Rodgers_Contents_R2_052104 MD: RODGERS, JOB: 03286, PAGE: v Copyright © 2004 by Taylor & Francis 7.SilicaandSilanes Walter Meon, Anke Blume, Hans-Detlef Luginsland, and Stefan Uhrlandt 8.GeneralCompounding Harry G. Moneypenny, Karl-Hans Menting, and F. Michael Gragg 9.Resins James E. Duddey 10.AntioxidantsandOtherProtectantSystems Sung W. Hong 11.Vulcanization Frederick Ignatz-Hoover and Byron H. To 12.CompoundDevelopmentandApplications George Burrowes and Brendan Rodgers 4871-9_Rodgers_Contents_R2_052104 MD: RODGERS, JOB: 03286, PAGE: vi Copyright © 2004 by Taylor & Francis Contributors Tonson Abraham Advanced Elastomer Systems, L.P., Akron, Ohio, U.S.A. Anke Blume Degussa AG, Cologne, Germany George Burrowes The Goodyear Tire & Rubber Company, Lincoln, Nebraska, U.S.A. Thomas F. Carlson Sid Richardson Carbon Company, Fort Worth, Texas, U.S.A. Howard Colvin Riba-Fairfield, Decatur, Illinois, U.S.A. Sudhin Datta ExxonMobil Chemical Company, Baytown, Texas, U.S.A. James E. Duddy Akron, Ohio, U.S.A. F. Michael Gragg ExxonMobil Lubricants & Petroleum Specialties Company, Fairfax, Virginia, U.S.A. Sung W. Hong Crompton Corporation, Uniroyal Chemical, Naugatuck, Connecticut, U.S.A. Frederick Ignatz-Hoover Flexsys America LP, Akron, Ohio, U.S.A. 4871-9_Rodgers_Contributors_R2_052104 MD: RODGERS, JOB: 03286, PAGE: vii Copyright © 2004 by Taylor & Francis William R. Jones Sid Richardson Carbon Company, Fort Worth, Texas, U.S.A. William Klingensmith Akron Consulting Company, Akron, Ohio, U.S.A. Hans-Detlef Luginsland Degussa AG, Cologne, Germany Colleen McMahon Advanced Elastomer Systems, L.P., Akron, Ohio, U.S.A. Karl-Hans Menting Schill & Seilacher ‘‘ Struktol’’ Aktiengesellschaft, Hamburg, Germany Harry G. Moneypenny Moneypenny Tire & Rubber Consultants, Den Haag, The Netherlands Walter Meon Degussa Corporation, Parsippany, New Jersey, U.S.A. Brendan Rodgers The Goodyear Tire & Rubber Company, Akron, Ohio, U.S.A. Byron H. To Flexsys America LP, Akron, Ohio, U.S.A. Andy H. Tsou ExxonMobil Chemical Company, Baytown, Texas, U.S.A. Stefan Uhrlandt Degussa Corporation, Piscataway, New Jersey, U.S.A. Walter H. Waddell ExxonMobil Chemical Company, Baytown, Texas, U.S.A. Wesley A. Wampler Sid Richardson Carbon Company, Fort Worth, Texas, U.S.A. 4871-9_Rodgers_Contributors_R2_052104 MD: RODGERS, JOB: 03286, PAGE: viii Copyright © 2004 by Taylor & Francis . York 12 7 01, U.S.A. tel: 80 0-2 2 8 -1 160; fax: 84 5-7 9 6 -1 772 Eastern Hemisphere Distribution Marcel Dekker AG, Hutgasse 4, Postfach 812 , CH-40 01 Basel, Switzerland tel: 4 1- 6 1- 2 6 0-6 300; fax: 4 1- 6 1- 2 6 0-6 333 World. Congress. ISBN: 0-8 24 7-4 87 1- 9 This book is printed on acid-free paper. Headquarters Marcel Dekker, Inc., 270 Madison Avenue, New York, NY 10 016 , U.S.A. tel: 21 2-6 9 6-9 000; fax: 21 2-6 8 5-4 540 Distribution and. Duddey 10 .AntioxidantsandOtherProtectantSystems Sung W. Hong 11 .Vulcanization Frederick Ignatz-Hoover and Byron H. To 12 .CompoundDevelopmentandApplications George Burrowes and Brendan Rodgers 487 1- 9 _Rodgers_Contents_R2_05 210 4 MD: