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Crosslinked Native Oils – Factice*Vulcanized Vegetable Oils

Information for the Rubber Industry

-KONTAKT 38

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 11

8. Influence of factice on the physical and chemical properties 13

9. Use of factice 17

Appendix

A. Dosage recommendations 20

B. Recipe examples 21-23

DOG 0113 Kontakt 38 engl. RZ 01.08.2003 10:45 Uhr Seite 25

-KONTAKT 38

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1. General information regarding factice 3

2. Structure 4

3. Analysis 4

4. Classification of factice in product groups 5

4.1 Sulphur factice 54.1.1 Brown sulphur factice 54.1.2 Yellow sulphur factice 54.1.3 White sulphur factice 64.2 Sulphur chloride factice 64.2.1 Sulphur chloride factice for

eraser production 64.2.2 Stabilized sulphur chloride factice 64.3 Factice for special elastomers 74.4 Peroxide factice 8

5. Compound mixing and viscosity 8

6. Processing of compounds containing factice 9

6.1 Injection moulding, transfer moulding, compression moulding 9

6.2 Extrusion/Calendering 106.3 Textile coating 10

7. Effects of factice on curing characteristics 11

7.1 Sulphur vulcanization 117.2 Peroxide vulcanization 12

8. Influence of factice on the phys-ical and chemical properties 13

8.1 Mechanical properties 138.1.1 Hardness 138.1.2 Elasticity 138.1.3 Compression set 138.1.4 Tensile strength 148.1.5 Tear strength 148.1.6 Abrasion 14

8.2 Resistance 158.2.1 Ageing resistance 158.2.2 Steam resistance 158.2.3 Ozone resistance 158.2.4 Weather resistance 158.2.5 Oil resistance 158.3 Other properties 168.3.1 Plasticizer absorption 168.3.2 Air permeability 168.3.3 Dynamic properties 168.3.4 Density 168.3.5 Surface appearance 168.3.6 Discolouration/Contact staining 168.3.7 Fogging 168.3.8 Electrical properties 17

9. Use of factice 179.1 Types of elastomers 179.1.1 Standard elastomers

(NR, IR, SBR; BR) 179.1.2 NBR 179.1.3 CR 179.1.4 IIR 189.1.5 EPDM 189.1.6 Special elastomers 189.2 Applications 189.2.1 Rubber erasers 189.2.2 Roller coverings 189.2.3 Profiles and hoses 199.2.4 Textile coatings 199.2.5 Calendered sheets 199.2.6 Hard rubber (ebonite) 199.2.7 Microcellular rubber products 199.2.8 Cable Covering 19

AppendixA. Dosage recommendations 20

B. Examples 21-23

Content

PagePage


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The development of crosslinked native oilsnamed factice occurred around the sameperiod as the discovery of the vulcanizationprocess (1839 sulphur vulcanization; 1846 sul-phur chloride vulcanization). A factice-likeproduct was already produced in the year1846 through oxidative treatment of rapeseedoil with nitric acid. The first sulphur facticewas produced in 1853 after further develop-ments in processing.

The main incentive for the development offactice, was the high price of natural rubberduring this period. Oil-sulphur-reaction-products only cost a fraction of the naturalrubber price. The French term “caoutchoucfactice” for rubber substitute gave factice itsproduct name in 1858.

Based on the ever increasing knowledge ofthe chemical and physical connections bet-ween the structure and properties of factice,one was able to manufacture consistent quali-ties. These were to be used firstly in naturalrubber, and later in synthetic elastomers.

Due to the decreasing price of rubber andthe increasing technological progress, facticewas increasingly used as a processing aid (seeTable 1) and is still used today in many areas ofthe rubber industry.

The major raw materials for the productionof factice are rapeseed oil and castor oil whichare reacted with sulphur, sulphur chlorideand hydrogen sulphide. Special forms of fac-tice are reacted with peroxide and diisocyana-tes. These can, however, only be produced bya few manufacturers.

In countries where soya is readily available(e.g. USA), soya oil factices are producedwhich are generally comparable to rapeseedoil factice.

Besides the vegetable oil and sulphur, addi-tional raw materials may be added to diffe-rent factice qualities which will alter its physi-cal properties, e.g. mineral oils, paraffinic oils,inorganic stabilizers and inorganic fillers etc.To produce the different types of factice, theraw materials and crosslinking agents aremixed and reacted at different temperatures.The reaction time can take up to several daysto complete and must follow precisely definedproduction parameters. The skill of producingfactice is the ability to produce a batch con-formity even though the raw materials usedmay differ in quality according to the season.

1. General information regarding factice*

*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 relevantliterature.

Advantages and effects of factice in rubber compounds

■ Shorter mixing cycles and easier mixing■ Energy saving due to lower temperatu-

res and shorter mixing cycles■ Improvement of plasticizer absorption

and retention■ Faster processing, coupled with closer

tolerance precision and improved sur-face appearance

■ Easier degassing and reduction ofporosity

Table 1

■ 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 grindingproperties

■ Improved dynamic cracking resistance


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2. Structure

The crosslinking with use of sulphur, sulphurchloride, hydrogen sulphide or peroxide pro-duces a spherical particle structure of 5 nm(which can be seen through an electronmicroscope) with a molecular weight of ca.50.000. This spherical structure explains the

influence of factice with regard to the rheo-logical properties of rubber compounds the socalled ball bearing effect. The spherical struc-ture also remains during mixing, processingand even after vulcanization.

Chemical bonding of the factice moleculesto the rubber molecules hardly occurs if at all.

The chlorine set free during the productionof sulphur chloride factice is bond to the α-carbon atoms adjacent to the crosslinkingsites. This crosslinking is of varying levels ofbond strength. A part of the bonded chlorinecan be eliminated by hydrolysis which produ-ces a vulcanization neutral sulphur chlorinefactice.*

Isocyanate factice is produced by crosslin-king the hydroxyl groups of native oils buil-ding urethane bridges. For peroxide facticecarbon bonds are built. Both these types ofnon-sulphur crosslinks have improved thermalstability.

In the past few years the best criterion forjudging the quality of factice became thetotal sulphur content. By using modern analy-sis equipment it is possible to control the qua-lity and to steer the production process.

To check the degree of polymerisation theacetone extract (AE) or the n-hexane extractvalues can be examined. These values may dif-fer extremely, depending on the time of mea-surement (duration of storage).

The free sulphur determined in the AE ofthe factice lies between <0,1 and 3%. The freesulphur can have an effect on the compoundscured with EV systems (low concentrations ofsulphur) if large amounts of factice are used.

The amount of inorganic additives can bedetermined by the ash content.

3. Analysis

Figure 2: Measurement of the complete sulphur content

Figure 1: Molecular structure of facticeSource: GAK 19, 1966, 232

*Sulphur chlorine retards the vulcanization.


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4. Classification of factice in product groups

4.1 Sulphur factice

The colour range of brown factice lies between dark and mid brown. DOG offers a range ofdifferent types according to individual properties.

4.1.1 Brown sulphur factice

Yellow sulphur factice is similar in molecularstructure to brown sulphur factice. The lightercolor is obtained by using refined hydrogen-

ated oils. Yellow sulphur factice is used wherethe light colour required excludes the use of abrown factice.

4.1.2 Yellow sulphur factice

Table 2

Product Colour Oil con- Total Sulphur Conforming Usetent (%) 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 0 16–19 +

F 25 brown 0 21,5–24,5 +

DS soft brown 30 9,5–12,5

K 14 D dark brown 0 13–16FG 140 dark brown 0 12–15PD 14 dark brown 15 12,5–15,5

Table 3


Gloria 17 yellow 0 15–18 +

Gloria L yellow 20 12–15 +

Hamburg 4 ochre 0 15–18 +

Hamburg M ochre 20 14,5–17,5

Gloria 17 FF yellow 0 15–18 +

Light coloured injection mouldedarticles, very soft compression moul-ded, transfer moulded articles, micro-cellular rubber, textile and roller co-verings, transparent rubber articlesFree-flowing version of Gloria 17

*Conforming to German food legislation

Dark coloured injection moulded,compression moulded, transfermoulded and free heated articles,linings/coatings, sealings for foodapplications, bottle rings, rollercoverings, hosesCompression moulded, transfermoulded and injection mouldedarticles based on hard rubber, po-lishable articles and linings/coatingsCompression moulded, transfermoulded and injection mouldedarticles, cable insulation, micro-cellular products, roller coveringsDark coloured injection mouldedarticles, cable insulation, floorcoverings, calendered sheets


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White sulphur factice is manufactured fromspecial refined rapeseed oil, sulphur andhydrogen sulphide.* It is specifically used in

manufacturing transparent, white and pastelcoloured rubber compounds.

4.1.3 White sulphur factice

*Mainly mono- or disulphidic crosslinking

4.2.1 Sulphur monochloride factice for eraser production

4.2 Sulphur monochloride factice

This factice is produced from rapeseed oil via crosslinking with sulphur chloride and additionalbasic substances.

4.2.2 Stabilized sulphur chloride factice

During the production of these white sul-phur chloride factice, the labile-bonded chlori-ne has been removed through hydrolysis aftertreatment with basic inorganic substances.

Stabilized sulphur chloride factice gives anexcellent dimensional stability to the rubbercompounds, as well as an exceptionally lowinfluence on the compression set.

Table 4


Corona R pastel 0 13,5–16,5 +yellow-white

Table 5


Nr. 12 white 18 3,5–6,5 Erasers, cold vulcanizationNr. 17 GW white 0 7,5–10,5 +

Table 6


Injection moulded and soft formHansa O ivory 0 6–9 + articles with an excellent dimensio-

nal stability, textile covering

Hansa F ivory 0 5,5–8,5 + Free-flowing version of Hansa O

Light coloured injection mouldedarticles, very soft moulded articles,microcellular rubber, transparentrubber articles,textile and rollercoverings


7

4.3 Factice for special elastomers

Special elastomers often require the use ofoil resistant factice made from castor oil.Dependent upon the colour requirements ofthe compound, Corona Q, NQ or RQ 18 can beused.

Should oil resistance in CR compounds be ofminor importance then types NP 17 and NC 12may also be used.

Produkt Colour Oil con- Total Sulphur Conforming Usetent (%) content % to BgVV*

Corona Q pastel 0 11–14 +yellow-white

NQ light brown 0 11–14 +

RQ 18 brown 0 19–22 +

NC 12 ivory 0 6,5–9,5

NP 17 brown 0 11,5–14,5

Table 7

Light coloured compression moul-ded, transfer moulded and injec-tion moulded articles made ofNBR/CR, roller coverings, calenderedsheets, printing sheets, articleswith swell resistance against petroland mineral oil (fuel hoses)

Coloured compression moulded,transfer moulded and injectionmoulded articles made of NBR/ CR,roller coverings, calendered sheets,printing sheets, articles with swellresistance against petrol and mine-ral oil (fuel hoses)

Dark coloured compression moul-ded, transfer moulded and injec-tion moulded articles made ofNBR/CR, roller coverings, calenderedsheets, printing sheets, articleswith swell resistance against petroland mineral oil (fuel hoses)

Special factice for compressionmoulded, transfer moulded andinjection moulded articles made of CR

Special factice for dark colouredcompression moulded, transfermoulded and injection mouldedarticles made of CR


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4.4 Peroxide factice

By crosslinking modified castor oil withperoxides, DOG produces a chlorine free whitefactice: WP

This is an ideal choice where extremely highvulcanization temperatures are required, for

example in LCM and UHF-processes andarticles requiring long term heat resistance.

In comparison to sulphur and sulphur chlori-de factice, WP offers the best compression setvalues.

5. Compound mixing and viscosity

Factice can be rapidly and uniformly dispersedinto the rubber compound using all standardmixing methods. In most cases it is recommen-ded that factice is added to the compound atthe beginning of the mixing process. The pre-sence of factice facilitates the mixing and im-proves the dispersion of fillers and plasticizers.

Compounds with substantial amounts of pla-sticizer are easily mixed and handled, as fac-tice has an excellent absorption and retentioncapacity for plasticizers.

Generally due to the better absorption offillers and plasticizers, a noticeable reductionin the mixing time can be achieved leading toa reduction in the use of energy.

As factice also helps decrease the inner fric-tion of the compound (ball-bearing effect), adistinct reduction in the mixing temperature isobtained. This can be seen in the followingstudy.

Due to the reduced process temperatureobtained by using factice, a certain protectioncan be archieved against premature onset ofcure (scorch).

Compounds containing factice are moreeasily sheeted off the mill, and show lessshrinkage than those not containing factice.

Table 8


Profiles and compression moulded,WP white 0 0 transfer moulded articles, especi-

ally for peroxide cure, erasers

Recipe

Table 9

phr phr

SBR 1502 60 60NR SMR CV 60 40 40CaCO3 65 65SiO2 15 15Carbon black for colouring 1 1ZnO 5 5Stearic acid 1 1F 10 (factice) 20

Release temperature 125 °C 105 °C

Internal mixer 35 l, mixing time: 5 min.


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6. Processing of compounds containing factice

The positive effect of factice on the flow ofthe compound can be seen by the increasedextrusion rate, reduced die swell, and a uni-form appearance even on complicated thin

lipped profiles. Another advantage of facticeis easier degassing which enables the manu-facture of non-porousarticles in open cure.

■ Improvement of extrusion rate■ Improvement of dimensional stability of

uncured compounds■ Improvement of calendering properties■ Better textile bonding properties

■ Smoother surface■ Reduction of density■ Velvety surface■ Improved building properties

Advantages of the use of factice

6.1 Injection moulding, transfer moulding, compression moulding

Test parameters

Laboratory extruder, 20 mm screwRound die, 3 mmMini-Garvey die area 7,06 mm2

Mixture: SBR / NR (compare Table 9)

By adding different factice grades, the flowand injection behaviour of compounds can beinfluenced. This can steer the working processof transfer moulding, compression mouldingand injection moulding. For example, due to shorter injection times, the moulds can be filled more rapidly, the production andheating times can be shortened and the

amount of defects is reduced. Factice enablesshorter cycle times, reduces air entrapmentand improves the mould release.

Factice provides better dimensional stability of uncured compounds and premoulds, andcounteracts the effect of cold flow duringstorage (e.g. compounds based on IIR or CSM).

Extrusion characteristics according to dosage

Table 10

Extrusion Diagramm ASTM

phr F 10 Surface quality according to ASTM D 2230

Figure 3

%

Extrusion speed Torque Swelling

6.2 Extrusion /Calendering

Improvement


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NR compound with 50 phr factice, without further additives.

Factice with plasticizer content show a reduced influence on dimensional stability of compounds,whereas Hansa O (without plasticizer) provides the best dimensional stability.

The calendering properties of rubber com-pounds are influenced in a similar mannerthrough factice as with extrusion. The mecha-nical requirements for both compounds aresimilar.

Factice enables the compound to deformwithout tension strain when passed throughthe calender nip/extruder head, and to retainits form.

Compounds containing factice calender withremarkable smoothness and uniformity. The

swelling after leaving the roll nip is reduced,as well as the longitude shrinking of thesheet. As a result, the so called calender effectis reduced in compounds containing factice, incomparison to those without. Additionallycalendered sheets containing factice, presenta pleasant surface texture after vulcanizationas is required by many applications. The com-pounds are also less temperature sensitive,which enables an easier handling during thecalendering.

The favourable influence in rubber solutionapplications has long been known. Compo-unds containing factice need less solvents toadjust the viscosity and are more consistentthan those without. There is also a reduced

tendency towards “strike through” and thespecified coat thickness is reached with a les-ser number of coating cycles. These facticecontaining compounds are less likely to threadand are easier to spread.

6.3 Textile coating

Comparison of dimensional stability improvement

Figure 4

Dim

ensi

on

a st

abili

ty in

dex

%

1: Hansa O

2: Corona R

3: F 10

4: F 14

5: F 17

6: DS soft


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Compounds containing factice can be curedin all conventional and modern vulcanizationprocesses including those using high tempera-tures. These compounds support the standardvulcanization cycles even at temperatures abo-ve 200°C, without decomposition. Our factice

WP is especially suited for these high tempera-tures. Polar factice, such as those based oncastor oil, can enhance the temperature effectduring microwave cure (UHF), and therebyaccelerate the curing process.

7. Effects of factice on curing characteristics

Factice tends to have a slight accelerating effect upon the scorch of rubber compounds

7.1 Sulphur vulcanization

Fig

ure

5

The influence on the cure time t90 may differ, dependent upon the factice type and dosage.

Fig

ure

6

Scorch time (t10) EPDM-Compound 836 E* Control 5 phr

10 phr20 phr

min

Curing time (t90) Compound 836 E* Control5 phr10 phr20 phr

min

Tab

le 1

1

EPDM base compound (S-System) 836 EKeltan 712 100Durex O 120Sunpar 150 50

Stearic acid 1ZnO 5

Deovulc BG 187 5Sulphur 1,5

*The graphics were constructed using mean values which were obtained in examinations within the temperaturerange of 160–200 °C.


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For peroxide vulcanization, it is preferable to use factice of the same crosslinking structure (WP)as it hardly influences the vulcanization.

7.2 Peroxide Vulcanization

Figure 7

The influence on curing time (t90) may differ dependand upon factice grade.

Curing time (t90) Compound 835 E*

Figure 8

min

Scorch time (t10) Compound 835 E*

min

Control 5 phr

10 phr20 phr

Table 12

EPDM base compound (Peroxid) 835 EKeltan 712 100Durex O 120Sunpar 150 50

Stearic acid 1ZnO 5

Perkadox 14/40 8Taic 70%ig 2

Control 5 phr

10 phr20 phr



13

By adding factice to elastomers with lowresilience, a substantial increase in elasticitycan be obtained.

In compounds characterized by high re-

bound resilience there is no change in elasti-city when factice is added. With increased fil-ler levels factice can be used to maintain therequired level of elasticity.

8.1.2 Elasticity (rebound resilience)

The influence of factice on the compressionset is dependand upon the grade and dosage.Generally the compression set will be increa-sed by adding factice.

The least influence is obtained with sulphurchloride factice (Hansa O) and peroxide factice(WP).

8.1.3 Compression Set

Compression Set 24 h/100 °C (Sulphur vulcanization)*

Figure 9

%

Control 5 phr

10 phr20 phr

8. Influences of factice on the physical and chemical properties

Through the addition of factice, very softcompounds can be produced with high plasti-cizer loadings. The plasticizer binding capacityof factice enables a reduction in the region of20 Shore A without the plasticizer migratingto the surface. Factice can also be used to pro-duce hard compounds (80 Shore A) as factice

containing compounds enable higher dosagesof filler, whilst keeping the favourable proces-sing properties.

For the production of Ebonite, F 25 is recom-mended.

8.1 Mechanical properties

8.1.1 Hardness



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In most cases factice will decrease the tensilestrength of rubber compounds.

In compounds with large filler content, smallamounts of factice can increase the tensilestrength as a result of its dispersion effect.

8.1.4 Tensile strength

The tear strength of compounds without fil-lers will be reduced by the addition of factice.This is explained by the fact that factice is nota reinforcing filler, nor does it generate a lowerstate of cure. The required tear strength canbe obtained by modifying the filler gradesand dosage. In high or medium durometer

compounds, an increase filler loading is re-quired to compensate the decreased hardnessinduced by factice. This will also reduce thenegative influence on tear strength.

An exception, however, is IIR, where facticeleads to a substantial increase in tear strength.

8.1.5 Tear strength

Rubber compounds containing factice showa higher abrasion than those without. For thisreason, factice is not used in products requi-ring high wear resistance such as tyre treads.When working with relatively small dosagesof factice as a processing aid, a detrimentaleffect on abrasion is hardly noted. On the

other hand high factice loadings increase theabrasion which is favourable for the produc-tion of rubber erasers.

These properties of factice, allow an excel-lent grinding of finished products i.e. rollercovers.

8.1.6 Abrasion

To obtain an ideal compression set in peroxide vulcanized compounds, the use of peroxidefactice (WP) is recommended.

Compression Set 24 h/100 °C (Peroxide vulcanization)*

Figure 10

%

Control 5 phr

10 phr20 phr



15

The ozone resistance of compounds basedon NR, SBR, NBR or IIR will normally not beaffected by the addition of factice. This isunderstandable, as the chemical structure offactice does not influence ozone attack on therubber polymer.

In diene rubber compounds the addition offactice necessitates an increase of waxes in the

recipe. This is due to the fact that facticeabsorbs the wax, decreasing the amount ofwax that migrates to the surface. For this rea-son it may be necessary to increase the dosageof antiozonant wax.

In CR compounds, factice improves the staticozone resistance. This is explained by thepositive influence of factice on the modulus.

8.2.3 Ozone resistance

The information regarding ozone resistance(see 8.2.3) is also relevant for the ageing pro-perties of compounds under tension.

The weathering of light coloured rubbercompounds which are not subject to tension

strain, is known to lead to surface effectssuch as crazing or frosting (frosting is not tobe confused with surface bloom of powderedcompound ingredients). In all DOG studies, nopositive or negative influence on the afore –mentioned effects could be ascertained.

8.2.4 Weather resistance

In NBR compounds, the addition of rape seedoil factice has lowered the oil resistance. Castoroil factices (Corona Q, NQ, RQ 18) affect the oilswell characteristics to a different degree, this is

dependent upon the ACN content (see Table 13)In CR compounds, the oil resistance proper-

ties can even be improved by adding castor oilfactice.

8.2.5 Oil resistance

Factice generally does not affect the staticheat- and long term ageing properties of rub-

ber compounds. An advantageous effect canbe obtained in dynamic articles (see 8.3.3).

8.2 Resistance

8.2.1 Ageing resistance

Factice does not suffer under the conditionsof open steam cure. The autoclave vulcanizati-on of compounds containing factice is a longestablished practice in the rubber industry.Also steam sterilisation of products containing

factice does not effect them negatively.

The hydrolysis of the ester crosslinks onlytakes effect when exposed to high tempera-tures for long periods of time.

8.2.2 Steam resistance


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As factice has a relatively low density, the incorporation in the rubber compound also reflectsthis redution.

8.3.4 Density

Free heated articles which are producedwith factice show a distinguished velvety sur-face touch, in contrast to the greasy, glossysurface of many factice-free compounds. Thefactice particles distribute uniformly through-out the rubber matrix and generate a micros-copically fine , ondulated surface whichexplains the pleasant, textile-like feel. Steamcured compounds using factice, rarely show

condensation spots on their dull velvet likesurface.

A further advantage of their surface structu-re is, that they offer a lower coefficient fric-tion towards glass and painted metals. This isan advantage when installing rubber profilesand replacing glass windows and panels.

8.3.5 Surface appearance

The rubber industry differentiates between discolouration and contact staining. In both cases, fac-tice does not have any negative influence what so ever.

8.3.6 Discolouration/Contact Staining

8.3 Other properties

8.3.1 Plasticizer absorption

When used in concentrations of max. 20 phr, factice does not affect the air permeability charac-teristics of the rubber compound even in IIR.

8.3.2 Air permeability

Factice frequently shows a favourable effecton the dynamic flexcracking resistance (as eva-luated in the DeMattia test). Factice tends toloosen the supermolecular structure of elasto-mers. This is shown by a decrease in modulus.

These benefits have traditionally been used inthe manufacture of shoe uppers. The incorpo-ration of factice has also improved the wetand dry grip.

8.3.3 Dynamic properties

Due to the better plasticizer retention, it is assumed that factice has an advantageous affectagainst fogging.

8.3.7 Fogging

Rubber compounds containing factice ena-ble the incorporation of larger amounts ofplasticizer and also prevent its migration tothe surface. Factice has proved to be effective

when mixing naphthenic plasticizers in CR.This also applies when large amounts of esterplasticizer are to be added to NBR e.g. softroller coverings.


17

NBR is often used for the production of oilresistant rubber goods. Its swell characteristicsare hardly affected by the factice grades

Corona Q, NQ and RQ 18. However the influ-ence of factice changes with changing levelsof ACN.

9.1.2 NBR

CR is often used, where the oil resistance isof minor or middle importance. CR offersexcellent weathering and ageing properties.

The Factice NC 12 (ivory) and NP 17 (brown)are especially suitable for this rubber type,and increase the injection flow considerably.

Naturally, castor oil factices and peroxidefactices can be used to improve the swellcharacteristics of CR.

9.1.3 CR

Factice WP is recommended for the peroxide vulcanization of NBR and also permits low com-pression set values.

Table 13

ACN-level Effect of castor oil factice

18-28% ACN-NBR Improvement of oil resistance33% ACN-NBR neutral

38-51% ACN-NBR Reduction of oil resistance

9. Use of factice

In the production of many extruded, ca-lendered and moulded articles factice is animportant indispensable ingredient in thecompound.

The reduction of the compound viscosity,the improvement of the injection flow, theincrease in dimensional stability and the im-proved plasticizer absorption and retentionare only a few of the reasons for using factice.(see dosage recommendations)

9.1 Types of elastomers

9.1.1 Standard elastomers (NR, IR, SBR, BR)

These properties in rubber compounds arehardly affected by factice. In cured articleswith resistance levels within the insulationrange (above 109 Ohm x cm) the presence offactice will decrease the results at best by a

factor of ten i.e. the antistatic area is not rea-ched. The electrical conductivity of compoundscontaining factice does not differ stronglyfrom those without when submerged inwater.

8.3.8 Electrical properties


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Factice can be advantageous in specialelastomers such as CSM, CO, EAM, PU, ECO,ACM if added in small dosages. The advanta-geous properties of factice i.e. plasticizerretention, structure building and degassing,can also be used in special elastomers. Sulphur

and chlorine free factice such as our WP, isoften used in special elastomers. One should,however, check in advance that the quality ofcompounds do not suffer when consideringthe advantages and processing properties offactice.

9.1.6 Special elastomers

Because of its low gas permeability, IIR isoften used for the production of inner tubesand liners as well as other extruded products.The affinity to cold flow, due to its thermo-plastic character, can be reduced with factice.The compounds containing factice, can beextruded faster, have a better dimensional sta-bility and can be welded better which is of

importance for bicycle and automobile innertubes. Furthermore, factice improves the re-silient properties and the tear strength.

This effect can clearly be seen in dark as wellas in light coloured compounds, even with highfactice dosages. The improved tear strength isa further reason why IIR is used in the produc-tion of bicycle and automobile inner tubes.

9.1.4 IIR

EPDM is well known for the production ofhigh 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 com-pounds to produce porous extrusions is mini-mized by the de-gassing capability of facticecontaining compounds. In many cases, evensmall amounts of factice enable the produc-tion of non-porous extrusions. This is of parti-cular interest for compounds processed in lesspressure curing units, such as LCM and UHF,

where up to 20 phr factice are often used. In microwave curing, some polar factices caneven contribute towards a faster heat riseunder UHF waves.

Factice has also established its value in res-pect of improving the welding characteristicsof EPDM, and for the manufacture of flexibleand supple sheeting.

Factice WP is especially suitable for peroxidecured EPDM compounds, giving the advanta-ge of a low compression set.

9.1.5 EPDM

In eraser compounds, factice represents thelargest ingredient with up to 400 phr. In thiscase, rubber is only present as binder for thefactice whose abradability is intentionally

exploited. Especially suitable are non-stabilisedsulphur chloride factice. Chlorine and sulphurfree peroxide factices (WP) are also used forthe production of erasers.

9.2. Applications

9.2.1 Rubber erasers

Roller covers containing factice accept morereadily the printing ink and give a sharpercontrast when printing. Also for the productionof extremely soft qualities (coverings with 20shore A) the only practical solution is to add upto 100 phr factice to obtain an ideal compound.

The good plasticizer retention and the goodbuilding up properties of compounds con-taining factice are also an important factor.

A better handling and a distinct improve-ment of the grinding capabilities can be obtai-ned by adding factice.

9.2.2 Roller coverings


19

When producing calendered sheets, theadvantage of factice is, that the compounddoes not stick to the roller. Also the air

entrapment is reduced, the form stability is safeguarded and a smooth surface isobtained.

9.2.5 Calendered sheets

To reduce the exotherme reaction in ebonitevulcanization, highly sulphured factice (F 25) isadded to the compound.

Ebonite is still able to be polished, when adosage of up to 25 phr is added.

9.2.6 Ebonite

In microcellular rubber products facticeimproves the dispersion of the compoundingredients and thus helps to obtain a uni-form pore distribution. Additionally, the hand-ling properties and the dimensional stabilityare improved.

Experience has shown that the grades Gloriaand Hamburg are especially suitable for micro-cellular rubber.

9.2.7 Microcellular rubber products

As with all extruded articles, the dimensionalstability, form stability, output and surfacequality are of great importance. The use offactice helps to achieve these attributes andenables a optimization of the productionprocess.

Factice enables an easier handling of thecompound and provides better grindingqualities.

Factice improves the welding properties ofthe components in coextrusion processes.

9.2.3 Profiles and hoses

The incorporation of factice in textile coatingcompounds generates primarily a pleasant vel-vet-like surface wich is similar to a textile sur-face. In the production of printing cloth theeffects are the same as with roller covering.

A further advantage is, that less spreadingsteps are required to obtain the desired coa-ting thickness.

9.2.4 Textile coatings

By incorporating peroxide factice (WP) inthe compound, the form stability and theextrusion speed of the cable can be increased.

This can be achieved, without having negativeeffects on its electrical properties.

9.2.8 Cable covering


-KONTAKT 38

20

Factice can be added in various dosages (5-400 phr). Because of the many differentapplications of factice, the following list can

only be seen as general guideline. Our tech-nical customer service department will gladlygive you further information.

Appendix

A. Dosage recomendations

Articles Dosage (phr) DOG factice gradesExtruded articlesGeneral purpose 15-30 brown/yellow/white sulphur factice, Hansa O, Hansa F rubbers (NR, IR, SBR)ACM 5-10 WPCR 10-20 Corona Q, NQ, RQ 18, NC 12, NP 17, WPCSM 10 brown/yellow sulphur factice, Hansa O, Hansa FECO 5-10 WPEPDM 10-20 brown/yellow/white sulphur factice, Hansa O, Hansa FIIR 10-20 brown/yellow/white sulphur factice, Hansa O, Hansa FNBR 10-20 Corona Q, NQ, RQ 18, NC 12, NP 17, WPPeroxide cured 5-15 WPcompoundsCalendered articlesGeneral purpose 15-25 brown/yellow/white sulphur factice, Hansa O, Hansa Frubbers (NR, IR, SBR)CR 10-15 Corona Q, NQ, RQ 18, NC 12, NP 17, WPCSM 10 brown/yellow/white sulphur factice, Hansa O, Hansa F,

Corona Q, NQ, RQ 18, NC 12, NP 17, WPEPDM 10-15 brown/yellow/white sulphur factice, Hansa O, Hansa FIIR 10-15 brown/yellow/white sulphur factice, Hansa O, Hansa FNBR 10-15 Corona Q, NQ, RQ 18, NC 12, NP 17, WPMoulded articles, Compression-, Injection- und Transfer-mouldingGeneral purpose 10-20 brown/yellow/white sulphur factice, Hansa O, Hansa Frubbers (NR, IR, SBR)ACM 5-10 WPCR 10-15 Corona Q, NQ, RQ 18, NC 12, NP 17, WPCSM 5-10 brown/yellow/white sulphur factice, Hansa O, Hansa F,

Corona Q, NQ, RQ 18, NC 12, NP 17ECO 5-10 WPNBR 10-15 Corona Q, NQ, RQ 18, NC 12, NP 17, WPPeroxide crosslinked 5-10 WPcompoundsRoller coverings60-70 Shore A 10 Recommendation depends on rubber typ, 50-60 Shore A 10-20 please contact our technical advisorsunder 50 Shore A 20-70 brown/yellow/white sulphur factice, Hansa O, Hansa F, under 20 Shore A 70-100 Corona Q, NQ, RQ 18, NC 12, NP 17Erasers 200-400 Nr. 12, Nr. 17 GWTextile coatings 10-20 brown/yellow/white sulphur factice, Hansa O, Hansa F,

Corona Q, NQ, RQ 18, NC 12, NP 17Microcellular products 10-20 brown/yellow/white sulphur factice Ebonite 5-25 F 25Transparent rubber articles 10-50 Corona R, WP, Corona Q

Table 14

}


21

B. Recipe examples

Influence of various factice grades (dosage 15 phr) on NR-compounds

Influence of various factice grades (dosage 15 phr) on NBR-compounds

Table 15

Table 16

Recipe Factice- Compression Set Tensile Elongation Hard- Re-grade (%) strength at break ness bound

22h/70°C 70h/20°C (MPa) (%) (Shore A) (%)

Hansa O 26 4 9,7 315 69 27NQ 26 5 10,9 410 65 25

RQ 18 26 6 12,0 400 68 24WP 17 4 9,5 350 68 27

Control 18 3 11,6 330 71 26


22h/70°C 70h/20°C (MPa) (%) (Shore A) (%)

Corona R 24 8 16,2 600 47 59Gloria 17 26 8 17,2 605 48 58

F 10 22 8 17,9 625 47 57F 14 24 8 17,2 605 47 58F 17 26 8 16,5 575 47 57

DS soft 24 9 17,6 625 48 59K 14 D 26 9 16,4 600 49 54PD 14 25 9 17,6 615 49 55

Hansa O 19 7 16,0 580 48 55Control 17 7 20,2 575 50 60

Smoked Sheets 100,0Carbon black N-550 25,0ZnO RS 5,0Stearic acid 2,0IPPD 2,0Controzon W 3,0Sulphur 2,2MBTS 1,1TMTD 0,15Factice 15,0

(Press cure, 20 min. at 145 °C)

NBR (33% ACN) 100,0 Carbon black N 770 50,0Stearic acid 1,0 ODPA 1,0 Sulphur 1,8CBS 1,1TMTM 0,1Factice 15,0



-KONTAKT 38

22

Influence of various factice grades (dosage 15 phr) on OE-SBR-compounds

Influence of various factice grades (dosage 15 phr) on IIR-compounds

Table 17

Table 18


22h/70°C 70h/20°C (MPa) (%) (Shore A) (%)

Corona R 32 12 9,0 270 62 25Gloria 17 32 13 9,7 280 61 24

F 10 31 14 9,5 350 62 24F 14 32 12 10,1 300 62 25F 17 29 12 9,8 330 63 24

DS soft 29 12 10,9 300 62 23K 14 D 31 13 10,3 315 64 22PD 14 31 12 9,9 290 63 22

Hansa O 32 12 8,5 270 64 23Control 33 16 10,9 320 64 22


22h/70°C 70h/20°C (MPa) (%) (Shore A) (%)

Corona R 33 6 9,2 625 55 12Gloria 17 35 5 9,0 615 52 12DS soft 37 5 10,1 640 54 13K 14 D 38 6 9,0 640 56 12

WP 26 10 7,5 610 56 11Control 22 8 10,9 585 62 9

SBR 1712 137,5Carbon black N-550 80,0Chalk 20,0Vaseline 10,0ODPA 2,0Controzon W 3,0ZnO RS 5,0Stearic acid 1,5Sulphur 2,2 MBTS 1,0DPG 0,2Factice 15,0

(Press cure 30 min. at 158 °C)

IIR 100,0Carbon black N-550 60,0Paraffinic oil 10,0Stearic acid 1,0ZnO RS 5,0Sulphur 1,5MBT 1,3TMTD 0,7ZDEC 1,0Factice 15,0

(Press cure 30 min. at 151 °C)


23

Influence of various factice grades (dosage 15 phr) on CR-compounds

Influence of various factice grades (dosage 15 phr) on EPDM-compounds

Impressum:Editor: DOG DEUTSCHE OELFABRIK Gesellschaft für

chemische Erzeugnisse mbH & Co KGD-20457 Hamburg, Ellerholzdamm 50 Tel. +49 (0)40/31 18 05-0 • Fax +49 (0)40/31 18 05-88E-Mail: [email protected]: www.dog-chemie.de

Authors: Henry Ahrens, Dr. Bernd BornemannJohn Chapman, Joachim Diederichsen Manfred Heide, Wolfgang Zech

Production: EHRENBERG WERBUNG Tel. +49 (0)40/27 09 45-0, Fax +49 (0)40/27 50 44

Use of text and pictures – even in extracts – is subjectto approval of the editor and is illegal to copyright.This also applies to copies, translations, micro recor-ding, saving on data carrier and/or commercial use ofaddresses and names especially sales to third parties.

Table 19


22h/70°C 70h/20°C (MPa) (%) (Shore A) (%)

Hansa O 17 4 9,9 575 47 39NC 12 21 5 9,7 570 47 37NP 17 22 4 11,6 710 41 38

NQ 25 5 11,1 625 45 33RQ 18 34 9 11,6 620 50 34

WP 24 9 9,0 530 51 39Control 19 6 13,4 715 47 39

Table 20


22h/70 °C (MPa) (%) (Shore A) (%)

Corona R 52 10,5 445 69 27Gloria 17 48 9,8 365 70 25DS soft 44 9,4 340 72 25K 14 D 38 9,0 335 72 24

WP 27 8,5 415 68 25Control 40 12,0 475 71 27

CR (mercaptan type) 100,0 Carbon black N-770 20,0Carbon black N-880 30,0Naphthenic oil 14,0Stearic acid 0,5ODPA 2,0Controzon W 2,0MgO light 4,0ZnO RS 5,0ETU 0,5Factice 15,0


EPDM 4% EN 100,0N 774 Carbon black 120,0Paraffinic oil 50,0ZnO 5,0Stearic acid 2,0Deovulc EG 3 4,0Sulphur 2,0Factice 15,0



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