1

Nº 14 The solution of zinc oxide dispersion and environmental protection in rubber

compounding --- through PCC’s Structure Controlled ZnO

Authors: Pan-Continental Chemical Co., Ltd, Taiwan

Hwei-Hwanga Chiou, Chia- Ming Chen, Juei-Lin Ou, Shu-Fen Yeh, Chia-Chun Chen.

Speaker:
Chia-Ming, Chen
Section Head of Research and Development in Pan-Continental Chemical Co., Ltd.
Mail: pcc21i@pccchem.com.tw
Phone: +886-4-26811401
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ABSTRACT
Zinc oxide is a widely known material as activators and thermal conductors during rubber
vulcanization process. However, the poor dispersing property and the environmental concern of
zinc oxide always bother the technicians and are eager to be conquered. The paper appears to be
over ambitions in its views of a revolution of zinc oxide, which is developed and investigated to
have better dispersion and distribution in rubber vulcanization as well as provide a solution for the
green trend.
In this paper, zinc oxide is introduced as a controllable structural module, crystallized zinc
oxide on the specific support by flake arrangement. CS-AZO® is named by Controllable Structure
Active Zinc Oxide. Due to specific structure controlled, CS-AZO® has low surface energy and
depolarization, which can cause better dispersion an distribution of particles in rubber compounds.
Additionally, the production process of CS-AZO® and rubber products are adopted an
environmental friendly solution by its controllable structural module, developing with less zinc
levels.
To examine the practical performance of CS-AZO® in rubber applications, we have selected
the representative formulas to compare with different Zinc oxide. Independent rubber test of
CS-AZO® was carried out the better performance on tensile strength and elongation. For normal
zinc oxide, it is difficult to achieve both in superior properties in rubber goods. However, CS-AZO®
accomplishes the difficult mission.

1. Introduction
Zinc oxide plays a significant role in rubber vulcanization as an activator or accelerator. A
considerable amount of rubber products’ manufacturers are thought that the higher zinc level, the
better physical properties. And, numerous studies have attempted to explain active zinc oxide with
high surface area reduce the dosage when compared to white seal.
One of the most significant current discussions is about environmental effects caused by zinc
oxide and researchers or manufacturers have shown the highly intention on reducing the levels of
zinc in recent years. Several studies were focus on finding potential substitutes for zinc oxide from
metal oxides such as calcium oxide, magnesium oxide…, but the results were not as expected.
Due to the presence of zinc oxide, the concentration of available Zn++ can increase the rate of
vulcanization. Traditionally, higher zinc level is commonly used in the industry as it is believed that it
is related to physical properties, aging resistance, and product stability. However, a major problem
for rubber compounding is poor dispersion of zinc oxide due to its high polarity.
The paper appears to be over ambitions in its views of a revolution of zinc oxide, which is
developed and investigated to the new generation of zinc oxide, controllable structure CS-AZO® to
reduce the zinc level. Its better dispersion and distribution in rubber vulcanization and its
characteristics provide a solution for the green trend.
This paper seeks to address the concept of increasing the availability of zinc in reaction by the
new generation design of zinc oxide. In this paper, zinc oxide is introduced as a controllable
structural module, crystallized zinc oxide on the specific support by flake arrangement. CS-AZO® is
named by Controllable Structure Active Zinc Oxide. It not only reduces the surface energy of zinc
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oxide but also decreases the polarity. The flake arrangement becomes the steric hindrance of zinc
oxide that lowers the attractive force between particles and improves its dispersibility. Thus, the
present CS-AZO® is effective in improving the compounds compatibility. Additionally, the
production processes of CS-AZO® and rubber products are adopted an environmental friendly
solution by less level of zinc - controllable structural active zinc oxide.

2. Experiments
2.1. Types of zinc oxide
The various types of zinc oxide are given in Table 1. The purpose of the experiments is to
evaluate the intercorrelation of zinc levels and structure.
Table 1. Types of zinc oxide
Type of zinc oxide Zinc level
White Seal Zinc 80%
Active Zinc Oxide Zinc 75%
CS-AZO® Zinc 45%

2.2. Compounding
To examine the practical performance of CS-AZO® in rubber applications, we have selected
the representative formulas to compare with different Zinc oxide.
Rubber compounds were prepared in a 3L internal mixer. Internal mixers consist of a chamber
to which the compounding ingredients were added to get a homogeneous compounding and used
roller mill to finish the vulcanization systems, then zinc oxide were added in a separated operation.
Each rubber compounds, vulcanization system and zinc oxide were provided in approximately 3.0
mm thickness, which was convenient for the subsequent preparation of 2mm thickness test
specimens. Table 2.1 to 2.5 display a series of model formulations on which further compound
optimization can be based.
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Table 2.1 Model small/bicycle tires formulation

Active Zinc
White Seal CS-AZO®
Compound Oxide
(Zinc 80%) (Zinc 45%)
(Zinc 75%)

NR#3 40 40 40
BR0150 30 30 30
SBR1500 30 30 30
UB4000 4 4 4
Stearic Acid 1 1 1
Aging Resistance, RD 2 2 2
Antiozonant, 7F 1 1 1
Carbon Black, CB220 30 30 30
Carbon Black, CB330 30 30 30
White Seal 5
Active Zinc Oxide 5
CS-AZO® 5
Sulphur 2 2 2
Accelerator, CBS 1.5 1.5 1.5

Table 2.2 Model inner tube - IIR formulation

Compound White Seal Active Zinc CS-AZO®
(Zinc 80%) Oxide (Zinc 45%)
(Zinc 75%)

IIR268 80 80 80
EP33 20 20 20
Resin, UB4000 4 4 4
Carbon Black, GPF 660 70 70 70
Softening Oil, P-200 25 25 25
Stearic Acid 1 1 1
White Seal 3
Active Zinc Oxide 3
CS-AZO® 3
Accelerator, TT 1 1 1
Accelerator, M-80 0.5 0.5 0.5
Sulphur 0.5 0.5 0.5
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Table 2.3 Model industrial parts - EPDM rubber goods formulation

Compound White Seal Active Zinc CS-AZO®
(Zinc 80%) Oxide (Zinc 45%)
(Zinc 75%)

EP33 100 100 100

Stearic Acid 1 1 1
Carbon Black, FEF 60 60 60
Carbon Black, HAF 60 60 60
Softening Oil, P-200 40 40 40
White Seal 5
Active Zinc Oxide 5
CS-AZO® 5
Accelerator for EPDM, 4 4 4
EG3 1 1 1
Sulphur

Table 2.4 Model industrial parts - CR compounds formulation

Compound White Seal Active Zinc CS-AZO®
(Zinc 80%) Oxide (Zinc 45%)
(Zinc 75%)

CR210 100 100 100

Magnesium Oxide 4 4 4
Stearic Acid 0.5 0.5 0.5
Aging Resistance, OCT 2 2 2
Clay 40 40 40
Carbon Black, FEF 20 20 20
Softening Oil, H-1 10 10 10
White Seal 5
Active Zinc Oxide 5
CS-AZO® 5
Accelerator, ETU 1.5 1.5 1.5

2.3. Curing
The cure characteristics as the minimum torque (ML), maximum torque (MH), scorch time (ts2)
and cure time (t90) were determined by using a Ektron Tek Rheometer (EKT-2000) according to
ASTM D2084.
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2.4. Characterization of Rubber Compounds

2.4.1. Hardness (Shore-A)
The hardness (Shore-A) of the rubber compounds was determined according to the ASTM
D2240 test method.

2.4.2. Tensile strength and elongation

Tensile strength and elongation were performed with a tensile testing machine (EKTRON
TS-2000) according to ASTM D412 test method using dumb-bell shaped test specimens at a
uniform speed 8.33 mm·s-1.

3. Results and Discussions

3.1. Morphologies of CS-AZO® and white seal

Figure 1. SEM images of CS-AZO®: (a) with 5,500 magnification; (b) with 10,000
magnification.

Figure 2. SEM images of white seal: (a) with 1,000 magnification; (b) with 7,000
magnification.

The conformational analysis of CS-AZO® is necessary to use SEM, Scanning Electron

Microscopy. The SEM images of Figure 1 indicate that the morphology of AZO CS is sphere-like as
a controllable structural module, crystallized zinc oxide on the specific support by flake
arrangement. Figure 2 presents the structure of white seal differently under SEM.
Interestingly, under the SEM, it was shown the aggregation of zinc oxide. White seal is
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seriously aggregated, compared with CS-AZO®. The particular flake structure of CS-AZO® forms
the steric hindrance and lower the attractive force between particles as well as improves the
dispersibility in rubber compounds.

3.2. Zinc Oxide Optimization of Rubber Compounds

3.2.1. Model small / bicycle tires formulation
The small / bicycle tires formulation according to Table 2.1 was investigated over a range of
zinc levels between white seal (Zinc 80%), active zinc oxide (Zinc 75%), and CS-AZO® (Zinc 45%)
to evaluate the vulcanization behaviors and physical properties with the same compounding
formula as well as the reducing CS-AZO® dosage was taken into account as shown in Table 2.5.

Table 2.5 Model small/bicycle tires formulation

Active Zinc
White Seal CS-AZO® CS-AZO®
Compounds Oxide
(Zinc 80%) (Zinc 45%) (Zinc 45%)
(Zinc 75%)

NR#3 40 40 40 40
BR0150 30 30 30 30
SBR1500 30 30 30 30
UB4000 4 4 4 4
Stearic Acid 1 1 1 1
Aging Resistance, RD 2 2 2 2
Antiozonant, 7F 1 1 1 1
Carbon Black, CB220 30 30 30 30
Carbon Black, CB330 30 30 30 30
White Seal 5 ----- ----- -----
Active Zinc Oxide ----- 5 ----- -----
CS-AZO® ----- ----- 5 3
Sulphur 2 2 2 2
Accelerator, CBS 1.5 1.5 1.5 1.5

Figure 3 below compares the intercorrelation of the vulcanization characteristics among the
different zinc level and different dosage of CS-AZO®. At the same dosage, 5phr, of zinc oxide and
CS-AZO®, it was found the shortened compounding time of CS-AZO®. Accordingly to the test
result, the MH of CS-AZO® is 3% lower and TC90 is 6% shorter than white seal.
As shown in Figure 4, the results obtain from a preliminary analysis of the physical properties.
The single most striking observation to emerge from the data comparison was a lower value for MH
and higher elongation was found accordingly to 5phr of white seal (Zinc 80%) and CS-AZO® (Zinc
45%). The correlation between 5phr white seal and 3phr CS-AZO® is interesting because the
structural controlled CS-AZO®, with less zinc level and reduced dosage, the physical properties
are comparable.
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In general, tensile strength and elongation should be inversely. However, CS-AZO®

accomplishes the difficult mission on high tensile strength and high elongation. The reason is the
better result on dispersion and distribution of CS-AZO® in rubber compounds. Meanwhile, the
shorten vulcanization time can be efficient the production process and increase the capacity.
CS-AZO®, the less zinc level, leads to a decrease in compounding time and therefore
progress the rubber processing and increase the capacity. CS-AZO® gives the following
improvements, in comparison with various zinc levels: improved physical properties, shortened
vulcanization time and increase the capacity.

30

27 5phr white seal (Zinc 80%)

5phr CS-AZO (Zinc 45%)
24 3phr CS-AZO (Zinc 45%)
5phr active zinc oxide (Zinc 75%)
21
Torque (kgf-cm)

18

15

12

9 5phr 5phr 5phr 3phr

Parameter white seal active zinc oxide CS-AZO® CS-AZO®
(Zinc 80%) (Zinc 75%) (Zinc 45%) (Zinc 45%)
6 min. Torque at / min (ML) 2.47 2.55 2.81 2.39
max. Torque at / min (MH) 22.61 22.55 21.95 21.51
3 TS2 / min 5.5 5.5 6.04 5.5
TC90 / min 12.12 12.57 11.31 11.34

0
0 2 4 6 8 10 12 14 16 18 20 22 24
Vulcanization Time (Min)

Figure 3.
Vulcanization characteristics of compounds for small / bicycle tires with different Zn levels,
white seal (Zinc 80%), active zinc oxide (Zinc 75%) and CS-AZO® (Zinc 45%) and with
dosage reduction on CS-AZO®. Temperature: 145℃ ℃; Time: 24 minutes.
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Figure 4.1
Properties of compounds for small / bicycle tires with different zinc levels and structure
5phr 5phr 5phr 3phr
ASTM
Properties white seal AZO CS-AZO® CS-AZO® Unit
Test Method
(Zinc 80%) (Zinc 75%) (Zinc 45%) (Zinc 45%)

Hardness, Shore A 70 72 72 70 (Å) D2240

Tensile strength 200 198 228 209 kg/cm2 D412
Elongation 350 345 410 370 % D412

Hardness Tensile Strength

72.5 235
230
72 225
71.5 220
Shore A

kg/cm2 215
71 210
70.5 205
200
70 195
69.5 190
185
69 180
5phr 5phr 5phr 3phr 5phr 5phr 5phr 3phr
white seal active zinc CS-AZO® CS-AZO® white seal active zinc CS-AZO® CS-AZO®
(Zinc 80%) oxide (Zinc 45%) (Zinc 45%) (Zinc 80%) oxide (Zinc 45%) (Zinc 45%)
(Zinc 75%) (Zinc 75%)

Elongation
420
400
380
%

360
340
320
300
5phr 5phr 5phr 3phr
white seal active zinc CS-AZO® CS-AZO®
(Zinc 80%) oxide (Zinc 45%) (Zinc 45%)
(Zinc 75%)

Figure 4.2
Comparison of physical properties in small / bicycle tires compounds with different zinc
levels.

3.2.2. IIR compounds for inner tube

As shown in Figure 5, the different zinc level and type of zinc oxide were used to investigate
the vulcanization performance of IIR compounds for inner tires with formulation listed in table 2.2.
The physical properties of IIR compounds shown in Figure 6 demonstrates that the
performance in hardness and tensile strength with different zinc level is insignificant, but it worth to
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mention that the elongation was enhanced distinctly by using CS-AZO®. Normally, elongation is the
index criteria for inner tube. Accordingly to the test result, there is a clear trend of CS-AZO® (with
zinc level 45%) accomplishes the difficult mission, greatly improving the elongation.

12.0
3phr white seal (Zinc 80%)
10.8
3phr active zinc oxide (Zinc 75%)
9.6 3phr CS-AZO (Zinc 45%)

8.4
Torque (kgf-cm)

7.2

6.0

4.8
3phr 3phr 3phr
3.6 Parameter white seal active zinc oxide CS-AZO®
(Zinc 80%) (Zinc 75%) (Zinc 45%)
min. Torque at / min (ML) 0.8 0.81 0.81
2.4 max. Torque at / min (MH) 9.83 9.74 9.29
TS2 / min 2.04 1.58 2.01
1.2 TC90 / min 7.16 6.43 5.42

0.0
0 1 2 3 4 5 6 7 8 9 10 11 12
Vulcanization Time (Min)

Figure 5.
Vulcanization performance of IIR compounds for inner tires with various ZnO as activator.
Temperature: 160℃℃; Time: 12 minutes.

Figure 6.1
Properties of IIR compounds for inner tube
3phr 3phr 3phr
ASTM Test
Properties white seal AZO CS-AZO® Unit
Method
(Zinc 80%) (Zinc 75%) (Zinc 45%)

Hardness, Shore A 53 53 53 (Å) D2240

Tensile strength 88 88 91 kg/cm2 D412
Elongation 485 527 600 % D412
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Hardness Tensile Strength

60 92
58
56
54 90
Share A

kg/cm2
52
50
48
46 88
44
42
40 86
3phr 3phr 3phr 3phr 3phr 3phr
white seal AZO CS-AZO® white seal AZO CS-AZO®
(Zinc 80%) (Zinc 75%) (Zinc 45%) (Zinc 80%) (Zinc 75%) (Zinc 45%)

Elongation
620
600
580
560
540
520
%

500
480
460
440
420
400
3phr 3phr 3phr
white seal AZO CS-AZO®
(Zinc 80%) (Zinc 75%) (Zinc 45%)

Figure 6.2
Comparison of physical properties of IIR compounds for inner tube.
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3.2.3. EPDM compounds

20
5phr white seal (Zinc 80%)
18
5phr active zinc oxide (Zinc 75%)
5phr CS-AZO (Zinc 45%)
16

14
Torque (kgf-cm)

12

10

8
5phr 5phr 5phr
6 Parameter white seal active zinc oxide CS-AZO®
(Zinc 80%) (Zinc 75%) (Zinc 45%)
min. Torque at / min (ML) 1.84 1.88 1.91
4
max. Torque at / min (MH) 13.32 13.44 12.91
TS2 / min 1.1 1.04 1.1
2 TC90 / min 4.12 4.06 3.47

0
0 1 2 3 4 5 6 7 8 9 10 11 12
Vulcanization Time (Min)

Figure 9.
℃; Time:
Vulcanization performance in industrial parts - EPDM compounds. Temperature: 160℃
12 minutes.

The curing curve of EPDM compounds are represented in Figure 9. The comparison of
different zinc oxide with the same EPDM compounds as Table 2.4 is to investigate the performance
of CS-AZO®, the controllable structure zinc oxide.
In Figure 9, the test results do not show a prominent increase or decrease in vulcanization
performance, which is different from the test results in other rubber compounds. The experiment is
interesting and reasonable that EPDM is single bond and saturation composition. Figure 10
presents the results obtain from a preliminary analysis of different concentration and type of zinc
oxide.
There was a significant positive correlation between CS-AZO® and white seal. CS-AZO®,
crystallized zinc oxide on the specific support, is consisted of a just half zinc level of white seal.
However, the physical properties and vulcanization performance of CS-AZO® has excellent results
as white seal. In the completion of CS-AZO®, the controllable structure module, providing the
better distribution and dispersion, were carried out the good performance and heading the right way
to the new generation product. Less zinc is more for environmental friendly and achievement of
physical properties.
The result appears to be over ambitions in its views of a revolution of zinc oxide, which is
13

developed and investigated to have better dispersion and distribution in rubber vulcanization as
well as provide a solution for the green trend.

Figure 10.1
Properties in industrial parts - EPDM compounds
5phr 5phr 5phr
ASTM Test
Properties white seal AZO CS-AZO® Unit
Method
(Zinc 80%) (Zinc 75%) (Zinc 45%)

Hardness, Shore A 76 76 76 (Å) D2240

Tensile strength 133 133 133 kg/cm2 D412
Elongation 304 305 306 % D412

Hardness Tensile Strength

80 140
130
70
120
Shore A

kg/cm2

60 110
100
50
90
40 80
5phr 5phr 5phr 5phr 5phr 5phr
white seal AZO CS-AZO® white seal AZO CS-AZO®
(Zinc 80%) (Zinc 75%) (Zinc 45%) (Zinc 80%) (Zinc 75%) (Zinc 45%)

Elongation
330
320
310
300
%

290
280
270
260
250
5phr 5phr 5phr
white seal AZO CS-AZO®
(Zinc 80%) (Zinc 75%) (Zinc 45%)

Figure 10.2
Comparison of physical properties in industrial parts - EPDM compounds.

3.2.4. Industrial parts - CR compounds

Zinc oxide is known as the accelerator for vulcanization. The results obtained from the curing
curve of CR compounds are presented in Figure 11. MH for active zinc oxide is higher than others
due to the characteristics of high surface area. Although the less zinc level is consisted, CS-AZO®
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has similar performance as white seal due to its structure controlled module.
CR is a high crystal rubber. Through the test result, CS-AZO® has both the highest tensile
strength and elongation, shows CS-AZO® has better dispersion and distribution in rubber
compounds.

20
5phr white seal (Zinc 80%)
18
5phr active zinc oxide (Zinc 75%)
16 5phr CS-AZO (Zinc 45%)

14
Torque (kgf-cm)

12

10

6 5phr 5phr 5phr

Parameter white seal active zinc oxide CS-AZO®
(Zinc 80%) (Zinc 75%) (Zinc 45%)
4 min. Torque at / min (ML) 1.29 1.3 1.29
max. Torque at / min (MH) 13.84 14.32 13.87
TS2 / min 1.37 1.4 1.34
2 TC90 / min 8.29 8.51 8.23

0
0 1 2 3 4 5 6 7 8 9 10 11 12
Vulcanization Time (Min)

Figure 11.
℃; Time:
Vulcanization performance of industrial parts - CR compounds. Temperature: 160℃
12 minutes.

Figure 12.1
Physical properties in industrial parts - CR compounds.
5phr 5phr 5phr
ASTM Test
Properties white seal AZO CS-AZO® Unit
Method
(Zinc 80%) (Zinc 75%) (Zinc 45%)

Hardness, Shore A 62 62 63 (Å) D2240

Tensile strength 162 163 167 kg/cm2 D412
Elongation 450 457 457 % D412
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Hardness Tensile Strength

64 168

166
Share A

kg/cm2
164
62
162

160

60 158
5phr 5phr 5phr 5phr 5phr 5phr
white seal AZO CS-AZO® white seal AZO CS-AZO®
(Zinc 80%) (Zinc 75%) (Zinc 45%) (Zinc 80%) (Zinc 75%) (Zinc 45%)

Elongation
460

455
%

450

445
5phr 5phr 5phr
white seal AZO CS-AZO®
(Zinc 80%) (Zinc 75%) (Zinc 45%)

Figure 12.2
Comparison of physical properties in industrial parts - CR compounds.

4. Conclusions
In this paper, CS-AZO® is introduced as a controllable structural module, crystallized zinc
oxide on the specific support by flake arrangement. The experiments were to evaluate the
influences and performance by the structure of zinc oxide. As discussed above, the effectiveness of
various zinc oxide with different zinc levels and structure as activator varied considerably in
different rubbers.
The controllable structure CS-AZO® not only reduces the surface energy of zinc oxide but also
decreases the polarity. The flake arrangement becomes the steric hindrance of zinc oxide that
lower the attractive force between particles and improves its dispersibility. Additionally, the
production process of CS-AZO® and rubber goods are adopted an environmental friendly solution
by controllable structural module – consisted less zinc level.
These findings further support the idea of CS-AZO® by evaluating and validating the feasibility
of reducing zinc levels through using controllable structural zinc oxide in rubber industry. The
investigations have shown that CS-AZO® with lower zinc levels possesses well performance and is
related to green products. It is called that the technology of CS-AZO® is the new generation of zinc
oxide and a new milestone in rubber industry.
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5. References
[1] J. E. Mark, Science and Technology of Rubber.1994, Academic Press: San Diego.
[2] A. V. Chapman, “Safe rubber chemicals: Reduction of zinc levels in rubber compounds”,
1997, TARRC/MRPRA.
[3] G. Heideman, J.W.M. Noordermeer, R.N. Datta and B. van Baarle, “Modified clays as
activator in sulphur vulcanisation”, 56, (2003), 650.
[4] G. Heideman, “Reduced zinc oxide levels in sulphur vulcanisation of rubber compounds”,
Ph.D. Thesis, University of Twente, Enschede, the Netherlands, 2004.
[5] G. Heideman, J.W.M. Noordermeer, R.N. Datta and B. van Baarle, “Effect of metal oxides
as activator for sulphur vulcanisation in various rubbers”, Kautsch. Gummi Kunstst., 58,
(2005), 30.
[6] G. Heideman, J.W.M. Noordermeer, R.N. Datta and B. van Baarle, “Various ways to reduce
zinc oxide levels in S-SBR rubber compounds”, Kautsch. Gummi Kunstst., 59, (2006), 178.