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CONTENTS
Page 1. Introduction to Latex Compounding and Processing 2. Methylmethacrylate Graft Polymer Latexes 3. Synthetic Latexes Produced by Emulsion Polymerization Styrene - Butadiene Latexes Carboxylated Styrene - Butadiene Latex High Surface Tension Acrylonitrile Butadiene Latex Elastomeric Carboxylated Butadiene Acrylonitrile Latexes Polychloroprene Latexes 10-15

17- 21
23-28 29-35 36-38 39-49 50-59 61-66 68-70 71-74 74-75 77-80 80"83 83 84-86 86-87 89-93 95-97 101 -108 109-112 113-115
117-119 119-122 123 123-127 98 100

FOREWORD
R. T.Vanderbilt Company, Inc., in keeping with its long tradition of service, is pleased to present this third edition of the Vanderbilt Latex Handbook to the rubber industry. The handbook has been compiled as a source of information for persons primarily engaged in the latex branch of the industry. It is intended to serve as a guide for the novice compounder so that laboratory and plant trials willgenerate meaningful data. Forthe experienced compounder, it is intended to serve as both a current and handy reference. Emphasis has intentionally been placed on the use of Vanderbilt compounding ingredients throughout the handbook. This was done in the belief that our product line of quality latex compounding materials is of sufficient depth that their use does not deviate from the acceptable principals and practices of

4. Latexes Producea by Solvent Polymerization Butyl and EPDM Latexes 5. Preparation of Ingredients for Compounding Preparation of Emulsions Preparation of Dispersions Preparation of Slurries 6. Vanderbilt Ingredient Dispersion and Emulsion Formulatory Accelerator Dispersions Antioxidant Dispersions Miscellaneous Dispersions Antioxidant Emulsions Caseinate Solutions 7. DARVANSurface Active Agents ". 8. Vulcanization Sulfur Crosslinking Zinc Oxide Cure Activation Acceleration of Cure Maturation and Precure of Latex Compounds Prevulcanized Latex Compounds

good latex compounl'ting.

.,

The use of-latex in commercial applications i~a specialized art and is protected by many patents. It is strongly recommended that a careful search of the patent literature precede any attempt to put either a latex compound or process into commercial practice. Robert Francis Mausser, Editor.

September 1, 1987

9. Antidegradants for Retardation of Degradation Causes and Symptoms of Degradation Antioxidants Ultraviolet Light Absorbers and Reflectors Antiozonants 10. Other Vanderbilt Compounding Materials DIXIEand McNAMEE CLAYS V~NPLAST PL Plasticizer and Softener VANCIDE51 Z Disper~ion Preservative RODO No. 0 and RODO No.1 0 - Reodorants VANGEL B - Thickener

129-130 130 - 131 132 - 133 133 - 134 134 - 135 137 - 140 141 -144 144 " 145 145 - 146 147

Robert F. Mausser retired from R. T. Vanderbilt Company in 1987 He is now consulting to the Latex Industry

11. FDAStatus of Rubber Chemicals Accelerators Antidegradants Dispersing Agents and Surfactants Miscellaneous Ingredients Subject for Regulations

I
149 152

12. Chemical Identification and Analysis of Rubber Products and Compounding Materials Identification of Elastomers Quantitative Determination of Sulfur in Rubber Compounds Quantitative Determination of TELLOY and VANDEX in
. Rubber Compounds

- 151
151

Tests for Copper and Manganese Examination of Mineral Fillers Identification of Vanderbilt Accelerators and Antioxidants Spot Test Identification of Accelerators and Vulcanizing Agents Infrared Spectroscopy 13. Vanderbilt Laboratory Test Methods

- 153 153 - 154 154 155 - 161

162 163

- 163

- 167

- Raw Materials

169 - 183

14. Latex Laboratory Procedures Testing of NR Latex Compounding and Testing of Films Health and Safety 15. Latex Hahdling in Bulk Systems 16. Dipped Gloves ~. 17. Halogenation of'bipped 18. Latex Tubing 19. Molded Goods 20. Paper Applications

185 187 188 190 190-191 193 - 196 198-206

Goods

208-210 212-215 217-219 221-223 225-229 230-243 245-247 248-253

CHAPTERl INTRODUCTION TO LATEX COMPOUNDING AND PROCESSING

21. Adhesives General Information Pressure Sensitive Adhesives 22. Addendum 23. Index

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INTRODUCTION TO LATEX COMPOUNDING AND PROCESSING

The art of latex goods fabrication was developed by natives of South America prior to the discovery of the New World. Natives, indigenous to areas where the rubber tree grew, produced items such as balls, waterproof clothing, water bottles and shoes directly from latex. While these first rubber processes involved fabrication of articles from latex, the latex goods industry showed little development until the second decade ofthe 20th century. Advances in both colloidal and organic chemistry rekindled interest in latex goods and their manufacture on a commercial scale. The development of synthetic latexes further reinforced interest in latex goods. Approximately 10% of all rubber goods produced today are derived directly from latex. Latex originally referred to a milky white substance occurring in certain trees and plants. Natural rubber latex is found in the Hevea brasiliensis (rubber) tree and guayule plant. The following definition, by D. C. Blackley, is a more current and suitable definition:

.I

Classification and Function of Compounding Materials

The ingredients used in latex compounding general classifications. 1) Surface active agents 2) Liquid phase modifiers 3) Elastomer phase modifiers may be divided into three

1. Surface Active Agents:

Water insoluble solid and water immiscible liquid compounding ingredients which are to be used as elastomer phase modifiers must be converted to water compatible systems which can then be mixed unifonnly into the latex without upsetting the colloidal stability of the latex system. The conversion is accomplished by using surface active agents and/or protective colloids to prepare dispersions and emulsions ofthe materials, thus rendering them useable for compounding latex. The surface active agents used are generally either anionic or non ionic. Anionic: Ionizable substances in which the anion is a great mass, negatively charged. Cationic: Ionizable substances in which the cation is the larger mass and is positively charged. Nonionic: Surface active materials which do not ionize and are active over a wide pH range. Amphoteric: Amphoteric materials are those which ionize differently to various conditions. Certain complex fatty amino compounds are in this class. Ingredients Class 1 Dispersing Agents Functions Disperse insoluble powders in water by placing an electrical charge on the individual particles. Examples The DARVANS: o 7 for nonN discoloring and non-staining applications. Nos 1 and 6 for broad spectrum use but slightly discoloring. No 2 for high solids dispersions, especially with clays and fillers where discoloration can be tolerated.
DARVAN 31, DARVAN WAO and DARVAN ME

Latex, either natural or synthetic, is a colloidal dispersion of a polymeric material in a liquid system mostly aqueous in nature. ",:, Film derived from raw latex does not lend itself to the production of either usable or saleable articles; its properties have to be modified. To accomplish this change, the latex must be compounded. Compounding involves the addition of various ingredients to the latex. Most of these ingredients will,at some point during the latex goods manufacturing cycle, modify the characteristics of the latex film, thus permitting the manufacture of commercial goods. Rubber and plastics are polymeric substances. The latexes discussed in this publication are known as elastomers. An elastomeric latex is one which after compounding hlcludes vulcanization as one of its processing steps. Vulcanized film derived from the latex must be capable of being stretched, under stress, to at least twice its original length. Upon release of stress the filmmust be capable of returning to approximately its original length. ISO 1382 Rubber Vocabulary, first edition 1972-10-15, defines vulcanization as a process in which rubber, through a change in its chemical structure (for example, crosslinking) is converted to a condition in which the elastic properties are conferred or reestablished or improved or extended over a greater range of temperatures. In some cases the process 'is carried to the point where the substance becomes rigid.

Wetting Agents

Emulsifying Agents

Lower interfacial tension to permit wetting out of dry powders. Disperse otherwise immiscible liquids.

Surface active agents as

DARVAN ME or DARVAN WAO. Soaps produced "insitu" by interaction of a base and

either fatty or rosin acids.

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2. Liquid Phase Modifiers:

Certain materials within this class protect the latex particle in the liquid state. They act to preve"t premature coagulation and prefloc formation during latex compounding and processing. Some materials act to modify certain liquid latex properties such as compound viscosity and wettability. Thus, processing characteristics of the compound are enhanced. Other materials within this class are capable of converting liquid compound directly to a solid (gelled) state.

3. Elastomer Phase Modifiers:

These materials impart to finished latex articles those properties desired by the compounder.

Ingredients Class 3
I. I

Function
Vulcanizing agent. Cure activator. Acts as vulcanizing agent in CR, XCR and XNBR Latexes. Control rate of vulcanization. Impart age resisting properties to finished products. Modify physical properties and reduce cost. Modify physical properties and cost. Control modulus of finished products. Mask typical rubber odors.

Sulfur Zinc Oxide Organic Accelerators Antidegradants Clays Other loading materials Softeners Reodorants

Class 2
Stabilizers

Function Maintain colloidal properties

Examples
pH modifiers: ammonia, caustic potash (KOH), caustic soda (NaOH), amines. Protective colloids:, high molecular weight materials such as: casein, glue, gelatin, and some synthetic gums. Surface active agents: DARVAN No.1, DARVANNo.6, DARVAN No.7, DARVANSMO, DARVAN ME, DARVAN WAQ and soaps. Natural gums: alginates, karaya gum, locust bean gum, casein, starches, gum tragacanth. Synthetic gums: methyl cellulose, hydroxyethyl cellulose, sodium carboxymethyl cellulose, sodium polyacrylate, neutralized carboxy vinyl polymers, RHODIGEL. Surface active agents: DARVAN No. 31, DARVAN WAQ, DARVAN ME and DARVAN NS. Soaps. Acids: Acetic, formic, glycolic, hydrochloric. Salts: Calcium nitrate, calcium chloride. Sodium and/or potassium silicofluoride. Quaternary amines, cationic soaps, diphenyl guanidine, Trimene Base.
.

Use of Elastomer Phase Modifiers

R = Required CR 654 & 671A R R R R 0 0 0 0 0

\
Thickeners Impart desired flow characteristics to latex compounds

0 = Optional

Latex Sulfur Zinc Oxide Organic Accelerators Antidegradants Clays

Other Loading Materials

NR R R R R 0 0 0 0 0

SBR R R R R 0 0 0

CR XSBR 571 R R R R 0 0 R R R 0 0 0 0 0

XCR 115 NBR XNBR IIR EPDM

-R

R R R R 0 0 0 0 0

0 R R R 0 0 0 0 0

R R R R 0 0 0 0 0

R R R 0 0 0 0 0 0

-R 0 0 0 0 0

Wetting Agents

Facilitate fiber impregnation, wetting properties, or decrease interfacial tension. 'Convert from liquid phase to solid elastomer rapidly. . Convert from liquid phase to solid elastomer slowly. Partially destabilize latex prior to gelation.

Primary Coagulants

0 0 0 0

Softeners Dyes and Pigments

Reodorants

Primary Gelling Agents Secondary Gelling Agents Heat Sensitizers

0 0

'Topermit gelationat
elevated temperatures.

Ammonium nitrate, ammonium persulfate, ammonium chloride, and polyvinyl methyl ether.

Many of the processes, products, and specific uses of individual materials in rubber manufacture are covered by a voluminous and complicated list of patents. It is suggested, therefore, that the reader make a careful search of the patent literature in his specific field before considering the adaptation of any compound or process described in the fOllowing sections.

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Compounds listed are of a general nature, designed to show the best potential uses of Vanderbilt materials. Every effort has been made to avoid the publication of what may be considered trade secrets and, to our best intent, no confidential information available through personnel transfer or participation in joint development programs has been revealed. Once the decision has been made to produce a specific product, the compounder must choose a latex which is to be used to fabricate the item. The latex selected must be capable after compounding and processing to impart those properties and performance features required of the finished product. Selection of a latex may be predicted on: 1) Physical properties 2) Chemical resistance properties of the latex film 3) Cost After a specific chemical type latex has been selected the compounder must choose between the different varieties within that type. Selection may be based on: 1) Ratio of monomers 2) Particle size 3) Particle size distribution The final choice of a specific latex, the plant equipment available to produce the goods al\d the service requirements of the finished goods determine what compound"mg materials are to be added to the latex.

Ifsmall particle size latex is to be blended with a latex of large particle size, additional stabilizer should be added to the latex with the larger particles prior to blending the two latexes. The smaller particle size latex should be added to that having the larger particles. The following latexes are available to the compounder.

Commercial
ASTM Designation NR MG
SBR XSBR NBR XNBR CR XCR IIR EPDM

Elastomeric

Latexes

Natural Rubber Methylmethacrylate Graft Polymer Synthetic: Produced by emulsion polymerization Styrene-Butadiene Carboxylated Styrene-Butadiene Butad iene-Acrylon itriIe Carboxylated Butadiene-Acrylonitrile Polychloroprene Carboxylated Polychloroprene Synthetic: Produced by solution polymerization Butyl Ethylene Propylene

Latex Blends
Any discussion pertaining tothe use of latex for fabrication of goods, would be incomplete if mention were not made of latex blends. Latex blends often are used to reduce compound cost. An example is the use of NRISBR Latex' blends for rug-backing. As the price of NR Latex increased, compared to that of SBR Latex, the amount of NR Latex in the blend diminished. Blends may also be desired to improve the performance of a product. Take for example a household glove. Some are made from two different latex compounds; each compound consists of a latex blend. The outer section of the film might consist of a blend of NR and CR Latexes. The tear resistance of this section of glove film is derived from NR Latex, which has poor oil resistance. The CR Latex in the blend improves the oil and ehemical resistance of the film. Likewise, the inner section of glove film may be comprised of an NRI NBR Latex blend. Cured NR Latex film is not very resistant to propagation of tear. NBR Latex in the film provides jagged (vs. straight line) tear, improving tear resistance of the film. The ozone resistance of NR Latex films is improved by blending NR Latex with either DuPont CR 400 or Burke-Palmason EP-603A(EPDM) Latex. Acidic and alkaline pH latexes should not be blended. Ifthere exists a wide spread inpHbetween the twolatexes tobe blended, their pHshould beadjusted prior to blending. The pH of the low alkaline pH latex should be adjusted upward; the pH of the high pH latex should be adjusted downward. The pH of both latexes should be approximately the same.