CABOT Carbon Blacks for rubber moulding articles.

New challenges for the industry through new products.

Presented at the EXPOBOR 2001
By Pedro M. Vicario,
CABOT, S.A. Zierbena Spain
ABSTRACT
The rubber industry, and the moulding article sector is not an exception, is facing every day
new problems and demands that are real challenges as new multi specification articles contain
highly demanding properties often seen as opposed and competing in performance values from a
traditional compounding practice viewpoint:
The hardness and modulus compete with the elongation at break.
The reinforcing properties, abrasion resistance and the like, compete with rubber elasticity and
good resilience.
The electrical resistivity competes with the addition of desired level of carbon black.
In other cases the process or manufacturing easiness is compromised:
Good compound fluidity with high hardness compounds.
Good and fast dispersion with high reinforcing fillers.
Additionally certain compounds are an obstacle to a normal manufacturing process due to
frequent filter pack clogging, premature mould fouling, difficult mould release, leading to
unexpected halts. We should not forget the demands for productivity gains or cost reduction
programs the industry is facing periodically, that imply new challenges under extreme operating
conditions, with increase in the number of cavities per mould, reduction of injection time with
smaller injection channels, shorter vulcanisation times at higher temperatures. What directions are
then taken to cope with the new demands?... Who puts the limit to this race?... Solutions are
stepwise devised and implemented by the actors counting on new processing equipment, new
materials and a flexible human staff able to accommodate and respond to the new challenges
through new procedures, with the new equipment and materials.
Cabot Corporation has introduced in the market new carbon blacks for the manufacture of
industrial rubber products, considering the needs expressed by an industry, used to take for granted
that the only choice of carbon black was restricted to the traditional ASTM N grades
A common need expressed by the rubber sector to the carbon black industry was for a better
or fast dispersion carbon black. This being a common claim is not easy to address with a single
solution since different specifications (reinforcing / hardness) are complied with using different
grades of carbon black. We will see that for the low reinforcing requirements, two grades:
SPHERON 6000 carbon black and SPHERON 5000 carbon black, could be used for the
SPHERON is a registered trademark of Cabot Corporation
good dispersion target, depending on the hardness / viscosity level of the final compound, with
excellent results, better than the ones obtained using traditional ASTM blacks. When a higher
reinforcement is required (similar to the one provided by the N300 ASTM series) the best balance
of dispersion/mechanical properties is achieved with the STERLING 6740 carbon black
A problem widely faced by the injection moulding sector and rarely address through the
filler system is the one of injection time or need for a low viscosity compound. The norm has been
the selection of a viable low viscosity polymer, and the extensive usage of processing aids with
corresponding drawbacks in elastic properties, mould fouling and extra costs. Despite the big effect
of the carbon black morphology, particularly structure, on compound viscoelastic properties,
traditional compounders have rarely used this route to respond to the problem. Why? Taking for
granted that the only grades of choice are the ASTM blacks or the non black fillers, the likelihood
for success was rather low. For this particular need, Cabot has developed a new low structure / low
surface area carbon black, SPHERON 4000 carbon black, that particularly at high hardness
compounding conditions yields the best balance viscosity / hardness in the more important
polymers used by the sector (NBR, EPDM) that help address the fast injection need with a
minimum usage of processing aids. Producers of injection moulded articles in large series are
considering as part of their variable costs, all expenses associated with the need of the mould
cleaning in the middle of a long run production schedule. This problem is exacerbated as the curing
temperature increases, which is the norm today, and assumed as unavoidable. Cabots new grade
SPHERON 4000 carbon black might help to delay the mould cleaning operation thanks to the
good compound flow obtained at low levels of processing aids.
As better performance is sought for rubber article components, new demands are added to the
specification list of the rubber part. Corrosion resistance under extreme conditions of a complex
component where a rubber part (joint, gasket, bracket, grommet,...) is in contact with a metal
surface is a typical case. The corrosion resistance of the whole component could be controlled
through the electrical resistivity of the rubber part. This is better achieved with the low surface area
SPHERON 6400 carbon black, at a decent loading avoiding the use of large amounts of non
black fillers and corresponding side effects on mechanical properties, compression set and other
elastic properties.
The SPHERON 4000 carbon black, SPHERON 5000 carbon black, SPHERON
6000 carbon black and SPHERON 6400 carbon black represent an alternative to traditional
ASTM grades, offered by CABOT to the industrial rubber product sector.
STERLING is a registered trademark of Cabot Corporation.
1 INTRODUCTION
The rubber industry, and the moulding article sector is not an exception, is facing every day
new problems and demands that are real challenges as new multi specification articles contain
highly demanding properties often seen as opposed and competing in performance values from a
traditional compounding practice viewpoint:
The hardness and modulus compete with the elongation at break.
The reinforcing properties, abrasion resistance and the like, compete with rubber elasticity and
good resilience.
The electrical resistivity competes with the addition of desired level of carbon black.
In other cases the process or manufacturing easiness is compromised:
Good compound fluidity with high hardness compounds.
Good and fast dispersion with high reinforcing fillers.
Additionally certain compounds are an obstacle to a normal manufacturing process due to
frequent filter pack clogging, premature mould fouling, difficult mould release,... leading to
unexpected halts. We should not forget the demands for productivity gains or cost reduction
programs the industry is facing periodically, that imply new challenges under extreme operating
conditions, with increase in the number of cavities per mould, reduction of injection time with
smaller injection channels, shorter vulcanisation times at higher temperatures. What directions are
then taken to cope with the new demands?... Who puts the limit to this race?...
Solutions are stepwise devised and implemented by the actors counting on new processing
equipment, new materials and a flexible human staff able to accommodate and respond to the new
challenges through new procedures, with the new equipment and materials.
CABOT Corporation has developed a new technology that has allowed to extend the
accessible reactor operational limits to produce carbon blacks with low surface area and / or
structure and to widen the possible spectrum of products. With this technology CABOT has
produced and tested carbon blacks with morphologies that help to respond to the new challenges the
industry is facing.
The new spectrum of commercial carbon blacks is depicted in figure 1, along with the
standard ASTM grades.
Figure 1
2 NEEDS
The most common need expressed by the industrial rubber sector to the carbon black
industry is for a better or for a fast dispersion carbon black. The driving force is the mixing cost
and its main elements: a) time, b) electrical bill, c) investment / depreciation.
A problem widely faced by the injection moulding sector and rarely address through the
filler system is the injection time that is not as short as desired or too long for certain applications
(high hardness parts). In these cases, the compounder use to try traditional ways to reduce the
compound viscosity (processing aids of any kind, low viscosity polymers, high filler loading, ...) as
product specification allows. The total part cost as a function of total cycle time, number of
possible cavities per mould, scrap rate due to improper mould filling ... is the main driver for this
need.
In connection with above problem but rarely admitted, the manufacturer of injection
moulding parts, sees that moulds gets foul sooner than expected as per old records or from previous
experience based on lower processing aids usage, different curing systems (sulphur versus
peroxide), lower curing temperature ... and other modifications adopted to improve productivity.
The control of the mould fouling is considered as a far reaching target and press halts for mould
cleaning are normally scheduled as an unavoidable step in long production runs of same part.
CARBON BLACK SPECTRUM
N358
VULCAN 5H
N115
VULCAN 9
N550
STERLING SO
N339
VULCAN M
N220
VULCAN 6
N134
VULCAN 10H
N234
VULCAN 7H
N326
REGAL 300
N330
VULCAN 3
N375
VULCAN J
N347
VULCAN 3H
N772
REGAL SRF
N660
STERLING V
N539
STERLING SO-1
N683
STERLING 105
STERLING 1120
SPHERON 4000
SPHERON 6000
SPHERON 6400
STERLING 6740
SPHERON 5000
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
0 20 40 60 80 100 120 140
STSA - Surface Area (m2 / g)
D
B
P
-

A




(
m
l

/

1
0
0
g
)
ASTM Grades NEW Grades
The industrial rubber sector is more and more supplying rubber parts to other industries
making more complex components needing seals, joints, gaskets, grommets, brackets, bellows,
supports, rubber stops etc. As better performance is sought for the final component, new demands
are added to the already long specification list of the rubber part. The corrosion resistance under
extreme conditions of a complex component where a rubber part is in contact with a metal surface
is a typical case.
3.1 Better dispersion
Using Cabots new semi-reinforcing technology, new black morphologies beyond the viable
limits of classical reactors are now possible and from them a few have been tested and selected for
their good potential in industrial rubber applications. They are shown in figure 1 and are already
offered and used commercially.
Among the new grades, the low surface area blacks with medium and high structure
SPHERON 6000 carbon black and SPHERON 5000 carbon black have the best potential for
very good and fast dispersion rate. They have been tested in EPDM formulations (see table 1)
adjusted to a hardness of 63 Shore A in comparison with the classical ASTM grades widely used by
the industrial rubber products sector: N550, N772, N660. The compounds were mixed in a BR
banbury, with a fill factor of 70%, a start mixing temperature of 30 C and a ram pressure of 40 psi.
The time of the 1
st
mixing step was of 110 seconds. The batch was finalised with the curatives in a
roll mill at 40 C during 7 minutes.
Table 1
Ingredients
Mix 1 Mix 2 Mix 3 Mix 4 Mix 5
EPDM (1) 100 100 100 100 100
Paraffinic Oil 75 75 75 75 75
Sulphur, 80% 1.25 1.25 1.25 1.25 1.25
STERLING SO (N550) 120 -- -- -- --
REGAL SRF (N772) -- 160 -- -- --
STERLING V (N660) -- -- 130 -- --
SPHERON 5000 -- -- -- 130 --
SPHERON 6000 -- -- -- -- 150
Zinc Oxide 80% 5.88 5.88 5.88 5.88 5.88
Stearic Acid 1 1 1 1 1
MBT, 80% 1 1 1 1 1
TMTD, 80% 1 1 1 1 1
(1) EPDM of high viscosity, low C
2
content and medium ENB content.
The main test results of the 5 compounds are given in table 2
Table 2
Mix 1 Mix 2 Mix 3 Mix 4 Mix 5
CB Grade
STERLING
SO
REGAL SRF STERLING
V
SPHERON SPHERON
(N550) (N772) (N660) 5000 6000
CB Loading, (phr)
120 160 130 130 150
Viscosity @100C
ML (1+4), (M.U.)
59 53 54 61 59
Hardness
Shore A, ( 3 sec.)
63 63 62 63 63
Volume Resistivity
Cabot T.M., (ohms.cm)
65 195 175 270 430
Tensile properties
Tensile Strength, (MPa)
13.5 12.2 13.3 12.2 11.3
Elongation @ Break, (%)
404 438 439 423 440
100% Modulus, (MPa)
3.6 3.0 3.2 3.9 3.7
300% Modulus, (MPa)
10.7 9.3 9.7 9.6 8.6
The viscositys of both SPHERON 5000 carbon black and SPHERON 6000 carbon
black compounds are similar to the viscosity of the N550 compound but higher than the viscositys
of either N772 or N660 compounds thanks to the carbon blacks structure and loading for the desired
hardness.
The tensile strength of the SPHERON 6000 carbon black is the lowest as might be
expected from its surface area but still at a very good level thanks to its tailor made morphology that
favour its good dispersion.
The dispersion of same compounds has been measured using an in-house developed rating
procedure. By this technique, the carbon black dispersion is evaluated by measuring and counting
the number of surface spots seen by a video camera on the surface of a thin standard tape freshly
extruded. A scheme with the basic equipment used is depicted in figure 2. A software especially
designed for this purpose, counts the number of spots detected by size (dark area) and the results are
displayed (number of spots by size range or above a certain size). The dispersion comparison of
above 5 compounds is given in table 3 and figure 3 as the number of surface defect counts above 80
microns found on the extruded tape.
Table 3
Mix 2 Mix 3 Mix 1 Mix 4 Mix 5
REGAL SRF
N772
STERLING V
N660
STERLING SO
N550
SPHERON 5000 SPHERON 6000
N of
defects >80
m
3743 3634 1774 889 705
Figure 2
The N550 is the best standard black for dispersion. It is notably better than the other two
standard carbon blacks included in this evaluation, N772 and N660, but it is clearly inferior to the
new morphology blacks, SPHERON 5000 carbon black and SPHERON 6000 carbon black, that
presented a comparatively low number of defects above 80 microns and a good processing and
mechanical properties as depicted in table 2.
Figure 3
"Tape defect counts (> 80 micron) vs. Carbon Black type"
0
500
1000
1500
2000
2500
3000
3500
4000
REGAL SRF
N772
STERLING V
N660
STERLING SO
N550
SPHERON
5000
SPHERON
6000
When a higher reinforcement, similar to the one provided by the N300 ASTM series, is
required, the best balance of dispersion / mechanical properties is achieved with the STERLING
6740 carbon black, a new high structure carbon black of intermediate surface area between the
N500 and N300 ASTM series.
For comparison purposes, four carbon blacks: N550, N358 SPHERON 5000 carbon black
and the STERLING 6740 carbon black have been evaluated in EPDM formulations adjusted to
the same hardness of 70 Shore A as shown in table 4. The compounds were mixed in a BR
banbury, with a fill factor of 70%, a start mixing temperature of 30 C and a ram pressure of 40 psi.
The time of the 1
st
mixing step was 3 minutes. The batch was finalised with the curatives in a roll
mill at 40 C during 7 minutes.
Table 4
Ingredients Mix 6 Mix 7 Mix 8 Mix 9
EPDM (1) 100 100 100 100
Zinc Oxide 7.5 7.5 7.5 7.5
Stearic Acid 1 1 1 1
Paraffinic Oil 70 70 70 70
Calcium Oxide 5 5 5 5
Sulphur 1 1 1 1
STERLING SO (N550)
120 -- -- --
VULCAN 5H (N358)
-- 90 -- --
SPHERON 5000
-- -- 132 --
STERLING6740
-- -- -- 110
MBT, 80% 1 1 1 1
TMTD, 80% 1 1 1 1
(1) EPDM of high viscosity, low C
2
content and medium ENB content.
The main test results of the 4 compounds included in this evaluation are given in table 5.
The viscositys of both N538 and STERLING 6740 carbon black compounds are similar
thanks to the counter effects of the different filler loading and structure, so that a similar processing
is expected for both compounds. The N550 and SPHERON 5000 carbon black compounds on the
contrary have a higher viscosity so better dispersion conditions are provided, but they also have the
higher carbon black loading.
Despite the different carbon black loading of the N358 and STERLING 6740 carbon black
compounds, the resilience as measured by the Zwick Rebound is similar, so no differences are
expected in elastic properties i.e.: compression set.
Table 5
Mix 6 Mix 7 Mix 8 Mix 9
CB Grade
STERLING
SO
(N550)
VULCAN
5H (N358) SPHERON
5000
STERLING
6740
CB Loading, (phr) 120 90 132 110
Viscosity @100C
ML (1+4), (M.U.) 70 64 71 65
Hardness
Shore A, ( max.) 71 70 70 70
Zwick Rebound
Rebound @ 23C, % 46 44 48 45
Volume Resistivity
Cabot T M, ohms.cm 220 110 1250 120
Tensile properties
Tensile Strength, MPa 14.4 15.6 13.2 15.2
Elongation@Break, % 352 402 345 400
100% Modulus, MPa 4.7 3.3 4.7 3.9
300% Modulus, MPa 13.1 11.6 12.4 11.9
The tensile strength of both N358 and STERLING 6740 carbon black compounds are
similar, despite the lower surface area of the new STERLING 6740 carbon black, the N550 and
SPHERON 5000 carbon black compounds have a lower tensile strength. Both N358 and
STERLING 6740 carbon black compounds also have similar elongation at break and higher than
the ones of the corresponding N550 and SPHERON 5000 carbon black compounds (that have a
higher modulus) mostly due to the different filler loading.
The similar tensile strength and elongation at break were the preconditions of this
comparison of STERLING 6740 carbon black with the N300 series black and this has been
achieved. The better tensile strength and elongation at break of the STERLING 6740 carbon
black versus the N550 and SPHERON 5000 carbon black compounds, might indicate a lower
mould tearing and scrap rate with the STERLING 6740 carbon black compound at a cost of the
lower carbon black loading for same hardness.
The dispersion evaluation of above four compounds has been made by observation at 25X
magnification of the surface finish of thin extruded tapes. The digital images of the photographs
taken at the 25X magnification of corresponding compounds are shown in figures 4, 5, 6 and 7.
Figure 4 Figure 5
STERLING SO (N550) VULCAN 5H (N358)
Figure 6 Figure 7
SPHERON 5000 STERLING 6740
It is clearly seen that the STERLING 6740 carbon black compound has much better
dispersion than the N358 compound. Both STERLING 6740 carbon black and N550 compounds
have similar levels of macro dispersion. The SPHERON 5000 carbon black compound shows the
best dispersion, as could be expected from its morphology.
3.2 Lower viscosity
With the target to help compounders on the difficult task to reduce injection time of high
hardness compounds by other than traditional means (processing aids), Cabot has developed a new
grade of carbon black, known as SPHERON 4000 carbon black. It has a very low structure to
reduce viscosity in compounds with the SRF particle size (see figure 1).
In order to see its effectiveness, four NBR compounds have been prepared using
SPHERON 4000 carbon black and the classical REGAL SRF carbon black with hardness
adjusted to 73 and 85 Shore A (see table 6)
Table 6
Ingredients Mix 10 Mix 11 Mix 12 Mix 13
NBR (1) 100 100 100 100
Zinc Oxide 5 5 5 5
Stearic acid 0.5 0.5 0.5 0.5
Plasticizer 5 5 5 5
Anti oxidants 6 6 6 6
Processing Aids 3.5 3.5 5 5
REGAL SRF (N772) 80 -- 145 --
SPHERON 4000 -- 85 -- 154
Curatives 6 6 6.5 6.5
(1) 28% ACN
The main test results are given in table 7.
Table 7
Mix 10 Mix 11 Mix 12 Mix 13
CB grade REGAL
SRF (N772)
SPHERON
4000
REGAL
SRF (N772)
SPHERON
4000
CB loading, (phr) 80 85 145 154
Rheometer MDR
@ 160C
Min. Torque, (dNm)
1.5 1.6 3.4 3.2
Max. Torque, (dNm)
29.9 29.2 35.8 32.9
scorch 1, (min.)
1.2 1.2 2.6 2.8
scorch 3, (min.)
1.5 1.5 3.1 3.3
scorch 5, (min.)
1.7 1.7 3.4 3.5
T50, (min.)
2.5 2.5 4.2 4.3
T90, (min.)
4.3 4.1 6.1 6
Mooney viscosity
@100C
ML (1+4), (MU)
52 50 99 85
Hardness
Shore A, (3 sec.)
73 73 85 84
Tensile properties
Tensile Strength,MPa
15.4 15.3 15.1 15.5
Elongation at Break, %
343 424 141 182
50% Modulus, MPa
2.6 2.3 5.4 4.1
100% Modulus, MPa
5.1 4.2 12.2 9.7
300% Modulus, MPa
14.4 13.1 -- --
Crescent Tear
Tear Strength, N/mm
58 58 45 46
Comparing compounds of same hardness the cure rate has not been affected by the higher
loading of the SPHERON 4000 carbon black but the mechanical properties have been modified as
could have been predicted by the different structure of the new black. The tensile and tear strength
are similar for both carbon blacks within the hardness range analysed, but the SPHERON 4000
carbon black compound has a lower modulus and a higher elongation at break than the SRF control
compound at both hardness levels. This is a positive trend and should help reduce the scrap rate due
to hot tearing during the demoulding operation.
The most important feature of the SPHERON 4000 carbon black lies in its low oil
absorption that only contributes to a mild viscosity rise. This is particularly important at high
loading or high hardness compounding. Comparing the data at 85 Shore A, the SRF compound has
a very high viscosity (99 ML(1+4) at 100C) difficult to inject in complex moulds, on the contrary
the SPHERON 4000 carbon black compound with same level of processing aids has a much
lower viscosity, that most injection moulding manufacturers would like to specify.
In the case of the medium hardness the SPHERON 4000 carbon black effect in MU
viscosity is relatively moderate, and its feature could be use to reduce injection time or limit the
compound dependence on processing aids.
Even for low hardness applications for which low viscosity compounds are used, the small
Mooney viscosity measurable drop when replacing the classical SRF by SPHERON 4000 carbon
black is important in terms of compound flow. This has been verified with compounds in Table 8
Table 8
Ingredients Mix 14 Mix 15
NBR 100 100
Zinc Oxide 5 5
Stearic Acid 0.5 0.5
Plasticizer 3.5 3.5
Coated Sulphur 0.3 0.3
Anti oxidants 2.5 2.5
Processing Aids 2 2
REGAL SRF N772 70 --
SPHERON 4000 -- 74
Curatives 4.5 4.5
Test results
Rheometer MDR @ 160C
scorch 3, (min.) 3.8 3.9
T50, (min.) 4.7 4.9
T90, (min.) 6.5 6.7
Mooney viscosity @100C
ML (1+4), (MU) 38 37
Hardness
Shore A, (3 sec.) 60 60
Tensile properties
Tensile Strength,(MPa) 15.9 16.3
Elongation at Break, (%) 411 475
100% Modulus, (MPa) 2.8 2.3
300% Modulus, (MPa) 12.3 10.5
Crescent Tear
Tear Strength, (N/mm) 40 40
NBR compounds 14 and 15 with a 60 Shore A hardness and viscositys (ML1+4 at 100 C)
of 38 and 37 MU have been tested in a Rheo vulkameter (100 C Piston & Die temperature, 50 bar
injection pressure, 180 C Mould temperature) with the results shown in figure 8
Figure 8
A small difference in Mooney viscosity might be important in the complete mould filling
and scrap reduction, particularly in multicavity and complex moulds.
The special SPHERON 4000 carbon black morphology, yields a mild increase in viscosity
with filler loading that: a) contributes to a better compound flow, b) allows to formulate with
lower proportions of processing aids for similar flow or c) allows any intermediate solution. Any
of the above compounding techniques will delay the mould fouling by one of the following
mechanisms: lowering compound / metal friction or lowering radical concentration if less
processing aids are used. The optimum solution will also depend on the injection and curing
temperatures.
Figure 9
Plant trials have been run in an industrial press producing NBR O-rings of 70 Shore A
hardness. The normal operating conditions of the press were: Injection temperature of 70 C,
Mould temperature of 200 C, Total cycle time of 45 seconds.
0 5 10 15 20 25
Filling rate (%)
Rheo vulkameter filling rate of a 60 Shore A,
NBR compound
SPHERON 4000
23 %
SRF (N772)
18 %
Injection moulding trial with a 70 Shore A, NBR compound (cycle time: 45
seconds)
650
1450
0 200 400 600 800 1000 1200 1400 1600
C
a
r
b
o
n

B
l
a
c
k
Number of injection cycles before fouling
SPHERON 4000
SRF (N772)
Two different compounds were prepared for feeding the press, one based in SRF (N772) the
other containing SPHERON 4000 carbon black, and the number of injection cycles before the
mould needs cleaning were counted for both compounds.
The results are depicted in figure 9. The effect of the SPHERON 4000 carbon black in
delaying the press halt for the mould cleaning is clear.
3.3 Lower electrical resistivity
Metal corrosion problems are being detected and reported in automobile components with
the use of new materials (aluminium, magnesium) and the increase utilisation of electronic devices /
high voltage batteries. After a correlation between the electrical conductivity of radiator hoses and
the failure by cracking of their inner tubes was found, more attention is being paid to the electrical
properties of rubber components in contact with certain metal surfaces.
Rubber part engineers having experienced corrosion problems in the past or learning from
others experience, are either putting a maximum limit to the total amount of carbon black in the
rubber compound or a electrical resistivity specification to the part or a corrosion resistance test to
the component.
Table 9
Ingredients Mix 16 Mix 17 Mix 18 Mix 19 Mix 20 Mix 21
EPDM (1)
100 100 100 100 100 100
Paraffinic Oil
50 50 50 50 50 50
Zinc Oxide
5 5 5 5 5 5
Stearic Acid
1.5 1.5 1.5 1.5 1.5 1.5
Calcium oxide
5 5 5 5 5 5
Sulphur
1.5 1.5 1.5 1.5 1.5 1.5
'coated' CaCO
3
100 100 100 85 70 55
ASTM N550
82 --- --- --- --- ---
ASTM N772
--- 106 --- --- --- ---
SPHERON 6400
--- --- 106 113 120 125
Curatives
3.8 3.8 3.8 3.8 3.8 3.8
Total Weight
348.8 372.8 372.8 364.8 356.8 346.8
% Total fillers 52.2% 55.3% 55.3% 54.3% 53.3% 51.9%
% CB 23.5% 28.4% 28.4% 31.0% 33.6% 36.0%
(1) EPDM of high viscosity, low C
2
content and high ENB content.
The rubber compounder first reaction is to replace part of the carbon black by non-
conductive white fillers. Often they are surprised by the amount of a standard carbon black that
needs to be replaced to be on the safe side of the new electrical resistivity specification. The other
negative effect is the expected increase in compression set.
The carbon black that best comply with the reinforcing / electrical resistivity compromise at
a reasonable loading is the new Cabot semi reinforcing grade SPHERON 6400 carbon black (see
figure 1)
We have compared some standard carbon blacks with SPHERON 6400 carbon black at
different total filler and whiting levels in the EPDM formulas (72 Shore A hardness) shown in table
9. The main results are in table 10.
Table 10
Test results Mix 16 Mix 17 Mix 18 Mix 19 Mix 20 Mix 21
Rheometer MDR @170C
Scorch 3, (min.) 0.9 0.9 1.0 0.9 1 0.9
T50, (min.) 1.5 1.6 1.6 1.6 1.6 1.5
T90, (min) 6 9 7 7 6 6
Mooney Viscosity
ML (1+4) @100C, (M.U.) 67 58 71 74 76 78
Hardness
Shore A, (3 sec.) 72 72 72 73 75 75
Compression Set
Set 22h@100C, (%) 48 53 53 48 42 38
Volume Resistivity
log Rho (DIN 53482) 5.6 7.0 9.5 8.9 7.8 7.5
Tensile properties
Tensile Strength, (MPa) 10.5 9.5 8.3 8.7 9.2 9.9
Elongation @ Break, (%) 277 292 269 257 235 263
100% Modulus, (MPa) 4.1 3.6 4.3 4.7 5.3 5.4
200% Modulus, (MPa) 7.6 6.6 6.6 7.1 8 8.2
Among the classical ASTM blacks and to get the highest electrical resistivity, the SRF is the
best choice, thanks to its large particle size and low structure. When SPHERON 6400 carbon
black is used in same formulation and at same loading as the SRF, the electrical resistivity is
increased by more than two orders of magnitude. This impressive result gives the rubber
technologist more freedom and allows, maintaining reasonable good carbon black loading along
with non-conductive fillers, to comply with the new electrical resistivity limits.
Above electrical resistivity results are depicted in figure 10 against the filler loading for the
three carbon blacks used in this comparison
These results are brought about by the morphology of the new black. Its surface area is
beyond the classical limits of furnace blacks, and its medium structure, without impairing the
electrical resistivity, allows for a good dispersion rate, very important to minimise the formation of
electrical paths.
Figure 10
Important steps in rubber compounding usually have a price, in this case it is the higher
viscosity due to the higher structure of the SPHERON 6400 carbon black. The other are just
additional benefits thanks to the possibility to replace part of the non black filler(s), particularly the
compression set that is lower, as seen in table 10, when the white filler proportion is reduced.
4 CONCLUSIONS
1 - New carbon black grades produced with the new technology developed by CABOT
Corporation, are answers to new demands by the rubber industry.
2 - SPHERON 5000 carbon black and SPHERON 6000 carbon black are black grades
with best dispersion capability in the semi-reinforcing field. The STERLING 6740 carbon
black is the best choice in the ASTM N300 reinforcing level.
3 - The SPHERON 4000 carbon black is the solution to produce low viscosity and high
hardness compounds. It also helps to reduce mould fouling, particularly of NBR
compounds, thanks to the good compound flow properties achieved even with minimum
usage of processing aids.
4 - SPHERON 6400 carbon black is the furnace carbon black that imparts the highest
electrical resistivity to rubber compounds, and is the black of choice in cases of metal
corrosion problems.
Volumen Resistivity at various CB concentrations in EPDM compounds
(72 Shore A)
0
1
2
3
4
5
6
7
8
9
10
82 CB + 100 whiting 106 CB + 100 whiting 113 CB + 85 whiting 120 CB + 70 whiting 125 CB + 55 whiting
Carbon Black + Whiting loading, (phr)
L
o
g

V
o
l
u
m
e
n

R
e
s
i
s
t
i
v
i
t
y


(
D
I
N

5
3
.
4
8
2
)
ASTM N550 ASTM N772 SPHERON 6400
23.5 % CB 28.4 % CB 31.0 % CB 33.6 % CB 36.0 % CB
5 ACKNOWLEDGEMENTS
The author wish to express his thanks to the many people who contributed to the experimental
work presented in this paper. Thanks also to the helpful discussions I had with them in the preparation
of the report.