RUBBER

RUBBER is an elastic, springy substance that comes from the milky juice
of a certain plant; or it can also be made from chemicals in a factory.

I. History

At an early date, this substance was known only as a toy. It was only in
1770 when Joseph Priestly discovered that this material can rub out pencil
marks; and he gave the name “RUBBER”

It took another 20 years for the use of the rubber as a raincoat to become
a reality. In 1839, Charles Goodyear discovered that by adding sulfur and basic
lead carbonate to natural rubber and heating the mixture, a more useful product
especially known in the tire industry today is produced.

Until about 1939, only natural rubber was available.

II. PROPERTIES AND APPLICATION OF RUBBER

1. Stretchability – the ability to be drawn out or extended to its full length

without exactly returning to its original dimensions before stretching

2. Resilience – the ability to return to its original shape after distortion within
elastic limits.

3. Electrical Insulation – rubber is a poor conductor of electricity; thus used

as electrical wire covering, plugs, sockets

4. Resistance to Chemicals – used as stoppers, gaskets, tubings, tank

linings, and similar articles

5. Non – permeability to gas – diffusion rate of gases through rubber is very

slow; used as inner tubes or tires, as gaskets, packings, hose and gas
masks

6. Bonding properties – the stickiness of rubber makes more useful as an

industrial material used as an adhesive bonding to metal; fabrics and
leather

III. CLASSIFICATION OF RUBBER

1. Natural Rubber
 - it is the latex which is obtained by tapping Hevea Brasiliensis
trees (rubber tree). The rubber molecules present in this latex
are polymers made up of 5,000 units of isoprene:
- CH2-C(CH3)=CH-CH2-

2. Synthetic Rubber
- man – made rubber using raw materials from petroleum or coke;
has properties similar to natural rubber

3. Elastomers or rubber – like plastics

- materials which possess the flexibility properties of rubber but
has a basic chemical structure different from that of natural
rubber; examples include vinyl polymers

IV. VARIOUS GRADES OF NATURAL RUBBER

1. Ribbed Smoke Sheet

- used for the manufacture of tire treads and carcasses, footwear,
cable insulation

2. Pale crepe (thick or thin)

- cleaner than other types and is good for translucent or light
colored goods

3. Latex
- used for impregnating, dipping or sponge applications

4. Guayule
- has a high resin content; is very soft; used to give other rubber
material tackiness

5. Fine Para
- used for high grade spread (sheeting) goods, rubber thread,
wire and cable insulation, and cements

6. Blanket
- has a definite color and odor; contains foreign materials;
generally blended with smoked ribbed rubber

7. Browns
- are dark in color; variable in quality; generally blended with
other grades

8. Flat – bark crepe

- a low grade material with a considerable content of foreign
materials and is used in low cost articles
 V. SYNTHETIC RUBBER

1. Buta – diene – Styrene Copolymers

(Trade Names: SBR, Buna S)

1.1. similar to natural rubber in processing procedures and in

properties
1.2. compounded with natural rubber or other gums to upgrade
the inferior properties of the pure gum stock
1.3. slightly superior than natural rubber in its aging properties
1.4. resistant to deterioration due to heat; slightly better than
natural rubber
1.5. natural rubbers have better resistance to oil, oxidizing
agents, aromatic solvents, chlorinated solvents
1.6. are treated with sulfur and accelerators to form vulcanates;
can also be cured to form hard rubbers
1.7. these forms of synthetics are the general purpose
substitutes for natural rubber

2. Isobutylene – Isoprene Copolymers

(Trade Names: Butyl)

2.1. closely resembles the natural rubber in many properties

2.2. also resembles the natural rubbers in their processing
characteristics
2.3. can also be vulcanized with sulfur and accelerators but at a
much longer time than natural rubber
2.4. has a low permeability for gases
2.5. has a more superior heat resistance than natural rubber
2.6. resistant to vegetable oil, lard and oleic acid
2.7. resistant to aging, to sunlight and to ozone
2.8. resistant to strong acids like HNO3, H2SO4, HF
2.9. combustible
2.10. used as inner tubes in tires, gas masks, tank linings

3. Chloroprene (chlorobutadiene polymers)

(Trade Name: Neoprene)

3.1. cannot be vulcanized with rubber; cannot be cured into hard

rubber; curing is done through other means
resistant to swelling and deterioration in petroleum oils, aging; to deterioration by
heat, sunlight, ozone; and to attack by most chemicals
Uses:
for oil – resistant hose
for gaskets which resists attack by lubricating oils even at high temperatures
for conveyor belts that must carry warm or oily materials
for barrage balloons which must be fire resistant
for the outer sheaths of electrical insulation which must be fire resistant
for heavy – duty tires

4. Butadiene – Acrylonitrile Copolymers

(Trade Names: N –type; Buna N; Butaprene; Hycar; Chemigum;
Paracril)

4.1. can be vulcanized with sulfur and accelerators; can be cured

into hard rubber
4.2. resistant to water absorption
4.3. has a better resistance to ozone than the natural rubber
4.4. has superior resistance to oil and most organic solvents than
natural rubber
4.5. has a better heat resistance than the natural rubber
4.6. is stronger than the styrene rubbers but not as strong as the
natural rubber
4.7. compatible with natural rubber as well as with many other
substances like plastics
4.8. more difficult to process than natural rubber
4.9. has a poorer resistance to cold than the natural rubber
4.10. deteriorates under sunlight
4.11. electrical properties are slightly inferior to those of natural
rubber
4.12. Uses:
4.12.1. used as a blending material, especially
with phenolics and vinyls among the plastics
4.12.2. used in combination with some natural
rubber for oil and gasoline hose, printer’s
blankers, gaskets, packings and tank linings
4.12.3. used for conveyor belts, wire
insulations, automobile parts

5. Polysulfide Rubbers
(Trade Name: Thiokols)

5.1. least like natural rubber and resembles some of the

elastomeric plastics (vinyls)
5.2. best among those which are resilient to oil
5.3. has a high resistance to chemical reagents, swells slightly
with active solvents (acetone and carbon tetrachloride)
5.4. is highly resistant to ozone, sunlight and aging
5.5. strength properties:
 - resistant to cold flow
- resistant to abrasion
- poorly resistant to high temperatures
5.6. lacks resilience
5.7. Uses:
5.7.1. for hoses and other similar tool in the refineries
and oilfields
5.7.2. for gaskets and packings
5.7.3. for linings of tanks used for petroleum storage
5.7.4. for additive of solid cements and special
sealants

VI. ELASTOMERS OR RUBBERIZED PLASTICS

These are certain flexible plastics, such as vinyl polymers, in

which flexibility is obtained by incorporating a “plasticizer”, usually a liquid, in the
material. These substances resemble the natural rubber or the synthetic rubber
in terms of their flexibility but they differ in chemical composition.

VII. HISTORY OF VULCANIZATION

In its early years, rubber articles were very soft and sticky in hot
weather; soft and brittle in cold weather; and soon after lost its elasticity. In
1839, Charles Goodyear was credited for the discovery of the cure when he
accidentally dropped a bit of the mixture of sulfur and rubber on his kitchen stove.
The lump became charred and tough; but, it remained tough and elastic in both
hot and cold. The process which consisted of heating the mixture of rubber and
sulfur became known as “vulcanization” for Vulcan, the Roman God.

VIII. RAW MATERIALS FOR RUBBER

1. Latex – the main component

- the sap of the tree for natural rubber
- coal made into styrene and butadiene made from petroleum for
synthetic rubber

2. Preservative – used to preserve the latex especially for natural rubber

- examples: ammonia, formalin
- Advantages in using formalin as preservative:
1. stops the bacterial and enzymatic actions
2. forms a stable latex
3. prevents oxidation to take place
4. is cheaper

3. Coagulant – used for the coagulation of latex

- examples of coagulants used
 1. acids – formic acid, HF, H2SO4
2. acidic salts – sodium bisulfate, calcium chloride,
strontium chloride
3. alcohol
4. Sulfur – is added vulcanization
- determines the elasticity of the rubber:
- a small amount of sulfur forms a very elastic material like rubber
band
- a big amount of sulfur added forms a very hard material like in
fountain pen cases

IX. OTHER MATERIALS ADDED TO RUBBER (COMPOUNDING

RUBBER)

1. Softeners and Plasticizers – make the rubber easier to mold

2. Fillers – materials added to give strength and wearing qualities to rubber

3. Antioxidants – chemicals added to slowdown the rate at which the

finished rubber combines with the oxygen gas in the air. This keeps the
finished rubber soft and pliable for years but eventually all rubber
combines with enough oxygen making it brittle.

4. Pigment – material added to give color to rubber

5. Accelerators – are materials added to hasten the vulcanizing processes

- simple vulcanizing is a long process which may take days; but
with the presence of a small amount of accelerator, the batch
can be cured in five minutes

X. MANUFACTURING PROCESS ACCORDING TO THE FLOW

CHART

A. NATURAL RUBBER

1. Tapping the latex from the tree involves:

1.1. making a spiral cut downward from left to right almost
through back
1.2. removing the bark shavings between each cut
1.3. the exposed latex ducts are then cut and the latex flows
down into the lowest cut and drips into a small cup
attached to the tree just below the cuts
1.4. the tapping is usually done in the morning when the sap
flows the fastest
2. The latex is diluted with water and mixed with preservatives and coagulants
at the station
3. When the rubber solidifies, it is placed in heavy rollers to squeeze out most
of the water
4. The resulting thin sheets of rubber are then brought to the smoke room
where it is being smoked in the shed full of timber smoke. The smoke dries
the sheets and kills any fungus that may be present or may start to grow
5. The rubber is then baled into sufficient sizes and is shipped for
manufacturing
6. When the rubber latex is shipped as a liquid instead of solid, it is mixed with
gaseous ammonia to prevent the latex from turning to solid and dreazy.
Much of the water present is removed and the latex is shipped in the
condensed form
7. If crepe rubber is desired, sodium bisulfate as well as formic acid, is added
and the rubber must be air dried.

B. SYNTHETIC RUBBER

1. Styrene, produced from coal, and butadiene, made from crude petroleum,
are mixed with a soap solution in a polymerizer unit to make a mixture of
high molecular weight substances
2. The resulting mixture formed is the latex. It is coagulated with a mixture of
salt and sulfuric acid
3. The rubber produced is in the form of crumbs like popcorn. It is dried by
passing it through hot air
4. The dried rubber is pressed into bales and is now ready for use by the
manufacturers.

XI. RUBBER PROCESSING

1. Milling – the latex solutions are mixed by a mechanical stirrer or by a ball

mill where no heat shall be generated which would result in a premature
coagulation
- crude rubber is subjected to a compressive and tearing action
by two rolls turning on each other at different speeds;
- this is done in order to overcome the elasticity or the “nerve” of
the crude rubber; and to form a homogeneous plastic which will
allow thorough mixing of the additives with the rubber
2. Extruding – the rubber strip is forced to the end of a cylinder which has an
orifice or die of the desired shape. The rubber compound is formed into the
desired shape when it is warmed up by the highly energetic processing and
ejected under pressure
- this is done in order to produce pieces of rubber items of
uniform/constant cross section like thread, tubes, rubber
gaskets for refrigerators
3. Calendering – this is done to produce sheets of definite thickness or to coat
rubber on fabrics
 - three or more rolls are arranged one above the other and
turning in opposite directions
4. Molding – this is done in heated, matched metal molds under high pressure
- this is done to produce non – porous uniform products of good
dimensional tolerances out of crude rubber
5. Dip Molding – this is used to produce hollow, seamless articles such as
balloons and rubber gloves using latex as the raw material
- the mold, which is usually aluminum, is coated with a layer of
coagulant and then dipped into the latex solution. When a
coagulated layer is formed on the mold, the mold is taken out of
the latex solution and is then subjected to vulcanization
- the mold can also be dipped first into the latex solution; then,
into a coagulant; and then, again, into the latex solution. After
coating the mold, it is subjected to vulcanization.
6. Spreading – this is used for making such things as rubberized fabrics. A
very thin layer of rubber is spread over the fabric.