Market leaders get more from every step of the value chain. That includes traditional steps such as manufacturing, purchasing and distribution but also information technology, commercial operations, customer service and chief executive involvement. The foundation of that leadership is a customer-focused culture that permeates all levels of the organization. Through strategic and skillful coordination of every aspect of the value chain and a commitment to making customers more profitable, organizations can make themselves more profitable in the process. They add more value for their customers, suppliers and shareholders and add more job security for employees. This presentation will provide examples of the solution-oriented value chain in action, including a description of how the Santoprene(TM) product line of ExxonMobil Chemical has excelled by adding value for customers.

This paper draws on the strengths of the International Rubber Study Group (IRSG) as the leading provider of economic and statistical information on the world rubber industry. The presentation, essentially non-technical in nature, provides a concise overview of the broad trends in production, consumption, trade and prices in the natural rubber latex (NRL) segment of the rubber industry at the national, regional (particularly with respect to Europe) and global level. Furthermore, in order to put NRL into context, its position relative to other types of NR is considered. While the main thrust of the paper is concentrated around NRL, the presentation will briefly touch on synthetic rubber lattices (SRL), particularly with respect to end uses and perceived material competition. One important conclusion drawn from the paper is that consumption of both NRL and SRL is greatest in producing countries, reflecting the existence of policies aimed at providing value-addition and high transportation costs.

The development of thermoplastic vulcanizates (TPVs) as a type of thermoplastic elastomers, has gained large technical and economic importance. TPVs are typically characterized by a chemically crosslinked rubber phase, embedded in a thermoplastic matrix, produced by dynamic vulcanization during mixing the rubber with the thermoplastic in the molten state. In the present work, the effects of different methacrylate-type co-agents as co-curing agents for peroxide vulcanization of PP/EPDM TPVs are reported, whereby the weight fraction of the EPDM vs. the PP is varied from 30, 50 to 70%. The methacrylates tested were: Ethylene glycol dimethacrylate (EDMA), Trimethylol propane trimethacrylate (TMPTMA, often referred to as TRIM) and Zinc dimethacrylate (ZDMA). Crosslinking was carried out at a fixed content of dicumyl peroxide with the amounts of co-agents varied. The purpose of the co-agents was to boost EPDM-crosslinking and at the same time prevent degradation of the PP by β-scission. Significant differences are reported: although all three methacrylates have the same ethylenic moieties as the reactive groups, the observed differences in mechanical properties point to diverse structures of the crosslink networks of the PP/EPDM TPVs. Out of the three co-agents, TMPTMA gives the best overall balance of properties, in EPDM crosslinking and preventing PP-degradation. This is explained by the positioning of the solubility parameter of this co-agent just in between those of EPDM and PP. The solubility parameter for EDMA is far away from either one. ZDMA, although giving very good room temperature properties like Tensile Strength, shows signs of thermo-reversion of the crosslinks in the Compression Set measured at 70 C.

This paper will address the factors to be taken into account when formulating rubber latices for dipping. Many products made from latices must comply with stringent regulations dictating performance and residual chemical content, and satisfying these requirements whilst meeting cost and environmental constraints provide the compounder with a multi-faceted challenge. This paper will describe the general principles, both practical and scientific, which underlie the compounding of natural and synthetic latices, including the selection and preparation of stabilizers, accelerators and antioxidants. Other aspects of formulation, such as blending different latices, incorporating fillers, pigments and plasticizers will be explored. The influence the formulation can have on dipping, film-forming, drying and other manufacturing operations will be discussed, and ways in which the latex compound can be made more environmentally friendly through reduction in materials, energy usage and effluent will be presented.

The paper deals with a study of fingerprints of several mixer lines for various compounds and situations. It will be shown that - arbitrary mixing process variations (like charging time of fillers) could lead to a mixing time variation of 10 –15% for the same degree of mixing - wrong chosen criteria to go into the next mixing phase (like thermocouple at low rotor speeds) could lead to variation in mixing quality in similar cycle times - the effect of cleaning the cooling system of the mixer body will lead to substantial improvement of the cooling behaviour of the mixer and herefore a better quality at same throughput rates - by optimising the mixing phases within the cycle the degree of mixing can be dramatically improved at the same mixing times.

5-vinyl-2-norbornene EPDM, (VNB-EPDM) is more efficient than 5-ethylidene-2-norbornene, (ENB-EPDM) in peroxide crosslinking, producing high cure state at low concentrations of VNB and peroxide. Recently a process for incorporating 5-vinyl-2-norbornene, (VNB), diene termonomer in the EPDM backbone was developed, resulting in a polymer with a high degree of long chain branching by Ziegler polymerization of the VNB pendent double bond and yet free of gel. For TPVs made by dynamic vulcanization of EPDM-polypropylene, it is advantageous to use lower peroxide levels to produce highly-crosslinked TPVs, in order to mitigate the undesirable degradation of the polypropylene. Through the use of these new VNB-EPDMs only a low level of VNB termonomer is necessary (<3 wt%) to produce TPVs with lower levels of peroxide and a high degree of cure. The resulting materials have improved elasticity resulting in up to 50% lower compression and tension set values than conventional phenolic resin cured TPVs. These new peroxide-cured TPVs based on VNB-EPDM have other useful attributes that include, lighter color, low moisture uptake and improved chemical resistance.

Joseph Talalay invented “Talalay process for latex” which leads to having an excellent open cell foam which is the best in the world for mattresses. Our presentation will describe the process and if possible we will like to show this in an 8 minutes video which is much more clarifying than any ppt. The process. In short we do following: We mix a compound varying from 100% natural latex to mixes containing 30% natural and 70% synthetic latex. We add soaps and some other products mix it in a mixer. We poor the material in a mould – which we seal with paper seal and then vacuumize. We freeze to minus 30 degrees Celsius which opens the cell and which creates the cell structure. (100) We bring air into the mould to make the product gel. We then heat to 115 degrees Celsius to vulcanize and following to that we put the product 8 hours in a 85 degree Celcius room in order to get it’s final shape. We measure, do quality checks, palletize and bring it to either shipping department or conversion for further customization. WHY DO WE HAVE ADDED VALUE. We will present to you the added value in a powerpoint in which we explain the differences with other foams in physical properties and especially we will address marketing. Compared to all other foams we produce the most ventilating breathing foam in the world which is also comfortable. Vita Talalay latex has the softest feel, gives the best support and elasticity and is ventilating. This means: • The best comfort for sleeping • Your body heat goes fast in, fast through, fast out. So the lowest sweaty from all foams. • It supports turning – makes turning easier than any other foam. We offer our products to the world’s highest end mattress producers. TEMPTED TO BED WITH VITA TALALAY LATEX.

This paper will consist of two parts: 1) A general overview on TPVs will be given, dealing with positioning of TPVs as thermoplastic elastomers, commercial production and suppliers, composition, morphology, properties and applications. The relationships between composition/morphology/properties/applications will be explained. 2) Results of recent experimental studies will be presented. The chemical mechanism of resol crosslinking of EPDM has been elucidated using low-molecular-weight model studies and via 13C NMR of resol-crosslinked 13C-labeled EPDM. The proposed cationic mechanism explains the reactivity of different EPDM grades. Increasing the number of substituents on the residual EPDM unsaturation results in enhanced reactivtiy for resol crosslinking. The dynamic vulcanisation process of EPDM/HDPE blends has been studied by taking samples along the extruder axis and determining the morphology and degree of crosslinking. Crosslinking of the elastomer phase already starts before melting of the thermoplastic phase. Upon melting the morphology is more or less immediately established, while crosslinking of the elastomer phase continues. For a 50/50 blend phase inversion from an EPDM matrix via a co-continuous EPDM phase to an EPDM dispersion is observed. Finally, the melt and solid state properties of the resulting TPVs will be correlated with the morphology and composition.

Unlike Natural Rubber latices Synthetic Polyisoprene and Carboxylated Nitrile latices are free from natural proteins and do not exhibit TypeI allergic reactions. However they are usually vulcanised with traditional Dithicarbamate and Thhiuram based accelerators. These are the precursors to Type IV skin allergy, potentially carcinogenic nitrosamines and contact discoloration.  This class of accelerators are extremely effective in Natural Rubber latices but have been found to be less effective in the synthetic latices. Novel accelerators developed by Robinson Brothers Limited have been shown to produce effective vulcanisation under a variety of production conditions whilst eliminating the problems associated with conventional dithicarbamates and thiurams. The paper will discuss the technological and scientific aspects of the novel accelerators along with the mechanisms of their actions in synthetic latices. It will also describe the accelerators action in High Ammonia Natural Rubber latex.

A new line of thermoplastic vulcanizates (TPVs) has been introduced by DSM Thermoplastic Elastomers for injection molding applications where UV resistance is critical. This new line of products, consisting of several grades with hardness ranging from 50 to 85 shore A in black color, shows superior flow characteristics and balanced properties meeting existing automotive material specifications. In this paper, we will discuss some of the features associated with this new line of products. After a short introduction on injection molding, specifically for TPVs, some basic properties of these new products are discussed, like crystallization behavior and cycle time. Most of these grades are formulated with the intention to increase their rate of crystallization over other commercially available TPVs. This ensures a faster solidification of the melt upon cooling, leading to a reduction in cycle time. A processing guideline gives information on the processing window of these new materials. Also some examples of typical applications in the automotive industry as glazing and sealing systems are included. As a conclusion: These high flow products are formulated to have low viscosity for ease of flow and better surface appearance. Through composition and process optimization, this product line is designed to offer excellent UV resistance, good fogging properties, and good mechanical and elastic properties with superior processability and consistency.

Latex formulations are typically designed using a wide variety of chemical ingredients, i.e. accelerators, activators, antioxidants and modifiers. These materials are added to the latex, during compounding, as separate waterbased dispersions. Masterbatches or a dispersion representing the combination of all the individual chemical dispersions, in the correct proportions, offers some significant advantages to the latex compounder. These advantages, namely, reduced stock keeping units (SKU’s), improved material control, improved accuracy of additions, reduced compounding time and finer dispersion particle size will be explored. In addition, particle size analysis using a laser diffraction analyzer will compare a variety of typical dispersion formulations, the change in particle size distribution during processing and the effect of dispersion particle size on the level of required chemicals in the latex formulation.

In early 2003 a new class of high performance thermoplastic vulcanizates (TPV) was commercially introduced. These materials have improved heat (150°C) and oil resistance (exceeding 3000 hours) and are composed of a continuous polyamide (PA) thermoplastic matrix with a dynamically vulcanized polyacrylate (ACM) thermoset . Many thermoplastic two-shot and insert molding processes can be easily adapted to utilize this new TPV material for soft-rigid overmolding. The overmolded part can then be utilized to improve the versatility of these materials in severe under-the-hood applications. A study was undertaken to demonstrate the overmold adhesion of this high-performance TPV to numerous common thermoplastic materials. The ACM//PA TPV is shown to have excellent adhesion to many of these thermoplastic substrates including polyamide and polyester.

The recovery and fatigue properties are compared for a range of different ‘soft’ thermoplastic vulcanizates (TPVs) based on dynamically vulcanised blends of NR and PP. The effects of rubber/plastic blend composition on fatigue behaviour have been investigated under conditions of constant stress and shown to be strongly dependent upon extension ratio and processing conditions. Comparisons are made with other TPV materials and the effects of blend morphology for these materials is discussed. Recovery properties, important for sealing applications, are contrasted for these materials using conventional ‘set’ and ‘stress relaxation’ methods.

The elastic properties of cross linked polyurethanes are excellent, however poor for linear PU’s. The morphology of linear PU is complex. PU segments have crystallized, have phase separated and have been dissolved on the low Tg polyether phase. Interesting would be to have a high elasticity at a as high as possible modulus. Studied is the effect of either crystalline structures or liquid-liquid demixed particles on modulus and elastic properties of segmented block copolymers. The concentration, length and length distribution of the hard phase is varied. Excellent combination properties were obtained with hard segments of uniform length that fully crystallized.

Development of new single site constraint geometry metallocene catalysts enabled to prepare copolymers of ethylene with higher α-olefins which have improved properties and better processibility compared to conventional polyolefin elastomers like EPDM, IIR etc. The copolymers can be elastomers or thermoplastic elastomers (TPE) depending on the comonomer content. These new polyolefin elastomers (commercially named as Engage) have poor compatibility towards polar polymers. Chemical modification via grafting is an interesting method of compatibilizing immiscible polymer blends as well as improving interfacial adhesion and technological properties in polymeric composites. In this investigation Engage has been modified by grafting with various materials like different (meth)acrylates, thioglycolic acid, maleic anhydride etc.. This kind of modification not only improves its interfacial properties but also other important properties. For example, grafting with hydroxyl ethyl methacrylate improves the biocompatibility of the elastomers. The grafting has been carried out by different methods. The different mechanical properties have been carried out and are compared with the unmodified polymer. The modified elastomers have been characterized by FT-IR, NMR, TGA, DSC, SEM, Zwick tensile machine.