EPDM is an M-Class rubber under ASTM standard D-1418; the M class comprises elastomers with a saturatedpolyethylene chain (the M deriving from the more correct term polymethylene). EPDM is made from ethylene, propylene, and a dienecomonomer that enables crosslinking via sulfur vulcanization. The earlier relative of EPDM is EPR, ethylene propylene rubber (useful for high-voltage electrical cables), which is not derived from any diene precursors and can only be crosslinked using radical methods such as peroxides.[5]
As with most rubbers, EPDM is always used compounded with fillers such as carbon black and calcium carbonate, with plasticisers such as paraffinic oils, and has functional rubbery properties only when crosslinked. Crosslinking mainly occurs via vulcanisation with sulfur but is also accomplished with peroxides (for better heat resistance) or phenolic resins. High-energy radiation, such as from electron beams, is sometimes used to produce foams, wire, and cable.
Properties
Typical properties of EPDM vulcanizates are given below. EPDM can be compounded to meet specific properties to a limit, depending first on the EPDM polymers available, then the processing and curing method(s) employed. EPDMs are available in various molecular weights (indicated in Mooney viscosity ML(1+4) at 125°C), varying levels of ethylene, third monomer, and oil content.[citation needed]
Because of chemical interactions, EPDM degrades when in contact with bituminous material such as EPDM gaskets on asphalt shingles.[6]
Relative to rubbers with unsaturated backbones (natural rubber, SBR, neoprene), rubbers with saturated polymer backbones, such as EPDM, exhibit superior resistance to heat, light, and ozone exposure. For this reason they are useful in external harsh environments.[9] EPDM in particular exhibits outstanding resistance to heat, ozone, steam, and weather. As such, EPDM can be formulated to be resistant to temperatures as high as 150°C, and, properly formulated, can be used outdoors for many years or decades without degradation. EPDM has good low-temperature properties, with elastic properties to temperatures as low as −40°C depending on the grade and the formulation.
EPDM is stable towards fireproof hydraulic fluids, ketones, hot and cold water, and alkalis.
As a durable elastomer, EPDM is conformable, impermeable, and a good electrical insulator. Solid EPDM and expanded EPDM foam are often used for sealing and gasketing, as well as membranes and diaphragms. EPDM is often used when a component must prevent fluid flow while remaining flexible. It can also be used to provide cushioning or elasticity. While EPDM has decent tensile strength, its flexibility makes it inappropriate for rigid parts such as gears, shafts, and structural beams.
A common use is in vehicles, where EPDM is used for door seals, window seals, trunk seals, and sometimes hood seals.[10] Other uses in vehicles include wiper blades,[11] cooling system circuit hoses; water pumps, thermostats, EGR valves, EGR coolers, heaters, oil coolers, radiators, and degas bottles are connected with EPDM hoses. EPDM is also used as charge air tubing on turbocharged engines to connect the cold side of the charge air cooler (intercooler) to the intake manifold.
EPDM seals can be a source of squeaking noise due to the movement of the seal against the opposing surface (and its attendant friction). The noise can be alleviated using specialty coatings that are applied at the time of manufacture of the seal. Such coatings can also improve the chemical resistance of EPDM rubber. Some vehicle manufacturers also recommend a light application of silicone dielectric grease to weatherstrip to reduce noise[citation needed].
This synthetic rubber membrane has also been used for flat roofs because of its durability and low maintenance costs.[12] As a roofing membrane it does not pollute the run-off rainwater (which is of vital importance for rainwater harvesting).[citation needed]
EPDM is also used for components that provide elasticity; for example, it is used for bungee cords, elastic tie-downs, straps, and hangers that attach exhaust systems to the underfloor of vehicles (since a rigid connection would transfer vibration, noise, and heat to the body). It is also used for cushioned edge guards and bumpers on appliances, equipment, and machinery.
Colored EPDM granules are mixed with polyurethane binders and troweled or sprayed onto concrete, asphalt, screenings, interlocking brick, wood, etc., to create a non-slip, soft, porous safety surface for wet-deck areas such as pool decks.[15] It is used as safety surfacing under playground play equipment (designed to help lessen fall injury).[15] (see Playground surfacing.)
Annual production of synthetic rubber in the 2010s exceeded 10 million tonnes annually and was over 15 million tonnes in triplets 2017, 2018, and 2019, only slightly lower in 2020.[16]
Further reading
Thermoplastic vulcanizates (mixtures of vulcanized polymers such as EPDM and immiscible polymers such as polypropylene).[17]
Related Research Articles
Vulcanization is a range of processes for hardening rubbers. The term originally referred exclusively to the treatment of natural rubber with sulfur, which remains the most common practice. It has also grown to include the hardening of other (synthetic) rubbers via various means. Examples include silicone rubber via room temperature vulcanizing and chloroprene rubber (neoprene) using metal oxides.
Petrochemicals are the chemical products obtained from petroleum by refining. Some chemical compounds made from petroleum are also obtained from other fossil fuels, such as coal or natural gas, or renewable sources such as maize, palm fruit or sugar cane.
An elastomer is a polymer with viscoelasticity and with weak intermolecular forces, generally low Young's modulus (E) and high failure strain compared with other materials. The term, a portmanteau of elastic polymer, is often used interchangeably with rubber, although the latter is preferred when referring to vulcanisates. Each of the monomers which link to form the polymer is usually a compound of several elements among carbon, hydrogen, oxygen and silicon. Elastomers are amorphous polymers maintained above their glass transition temperature, so that considerable molecular reconformation is feasible without breaking of covalent bonds. At ambient temperatures, such rubbers are thus relatively compliant and deformable. Their primary uses are for seals, adhesives and molded flexible parts.
An O-ring, also known as a packing or a toric joint, is a mechanical gasket in the shape of a torus; it is a loop of elastomer with a round cross-section, designed to be seated in a groove and compressed during assembly between two or more parts, forming a seal at the interface.
A flat roof is a roof which is almost level in contrast to the many types of sloped roofs. The slope of a roof is properly known as its pitch and flat roofs have up to approximately 10°. Flat roofs are an ancient form mostly used in arid climates and allow the roof space to be used as a living space or a living roof. Flat roofs, or "low-slope" roofs, are also commonly found on commercial buildings throughout the world. The U.S.-based National Roofing Contractors Association defines a low-slope roof as having a slope of 3 in 12 (1:4) or less.
Accelerants are substances that can bond, mix or disturb another substance and cause an increase in the speed of a natural, or artificial chemical process. Accelerants play a major role in chemistry—most chemical reactions can be hastened with an accelerant. Accelerants alter a chemical bond, speed up a chemical process, or bring organisms back to homeostasis. Accelerants are not necessarily catalysts as they may be consumed by the process.
A synthetic rubber is an artificial elastomer. They are polymers synthesized from petroleum byproducts. About 32 million metric tons of rubbers are produced annually in the United States, and of that amount two thirds are synthetic. Synthetic rubber, just like natural rubber, has many uses in the automotive industry for tires, door and window profiles, seals such as O-rings and gaskets, hoses, belts, matting, and flooring. They offer a different range of physical and chemical properties which can improve the reliability of a given product or application. Synthetic rubbers are superior to natural rubbers in two major respects: thermal stability, and resistance to oils and related compounds. They are more resistant to oxidizing agents, such as oxygen and ozone which can reduce the life of products like tires.
Butyl rubber, sometimes just called "butyl", is a synthetic rubber, a copolymer of isobutylene with isoprene. The abbreviation IIR stands for isobutylene isoprene rubber. Polyisobutylene, also known as "PIB" or polyisobutene, (C4H8)n, is the homopolymer of isobutylene, or 2-methyl-1-propene, on which butyl rubber is based. Butyl rubber is produced by polymerization of about 98% of isobutylene with about 2% of isoprene. Structurally, polyisobutylene resembles polypropylene, but has two methyl groups substituted on every other carbon atom, rather than one. Polyisobutylene is a colorless to light yellow viscoelastic material. It is generally odorless and tasteless, though it may exhibit a slight characteristic odor.
Polybutadiene [butadiene rubber BR] is a synthetic rubber. Polybutadiene rubber is a polymer formed from the polymerization of the monomer 1,3-butadiene. Polybutadiene has a high resistance to wear and is used especially in the manufacture of tires, which consumes about 70% of the production. Another 25% is used as an additive to improve the toughness of plastics such as polystyrene and acrylonitrile butadiene styrene (ABS). Polybutadiene rubber accounted for about a quarter of total global consumption of synthetic rubbers in 2012. It is also used to manufacture golf balls, various elastic objects and to coat or encapsulate electronic assemblies, offering high electrical resistivity. Polybutadiene is typically crosslinked with sulphur, however, it has also been shown that it can be UV cured when bis-benzophenone additives are incorporated into the formulation.
A polyolefin is a type of polymer with the general formula (CH2CHR)n where R is an alkyl group. They are usually derived from a small set of simple olefins (alkenes). Dominant in a commercial sense are polyethylene and polypropylene. More specialized polyolefins include polyisobutylene and polymethylpentene. They are all colorless or white oils or solids. Many copolymers are known, such as polybutene, which derives from a mixture of different butene isomers. The name of each polyolefin indicates the olefin from which it is prepared; for example, polyethylene is derived from ethylene, and polymethylpentene is derived from 4-methyl-1-pentene. Polyolefins are not olefins themselves because the double bond of each olefin monomer is opened in order to form the polymer. Monomers having more than one double bond such as butadiene and isoprene yield polymers that contain double bonds (polybutadiene and polyisoprene) and are usually not considered polyolefins. Polyolefins are the foundations of many chemical industries.
Nitrile rubber, also known as nitrile butadiene rubber, NBR, Buna-N, and acrylonitrile butadiene rubber, is a synthetic rubber derived from acrylonitrile (ACN) and butadiene. Trade names include Perbunan, Nipol, Krynac and Europrene. This rubber is unusual in being resistant to oil, fuel, and other chemicals.
An acrylate polymer is any of a group of polymers prepared from acrylate monomers. These plastics are noted for their transparency, resistance to breakage, and elasticity.
Thermoplastic olefin, thermoplastic polyolefin (TPO), or olefinic thermoplastic elastomers refer to polymer/filler blends usually consisting of some fraction of a thermoplastic, an elastomer or rubber, and usually a filler.
FKM is a family of fluorocarbon-based fluoroelastomer materials defined by ASTM International standard D1418, and ISO standard 1629. It is commonly called fluorine rubber or fluoro-rubber. FKM is an abbreviation of Fluorine Kautschuk Material. All FKMs contain vinylidene fluoride as a monomer. Originally developed by DuPont, FKMs are today also produced by many companies, including: Daikin (Dai-El), 3M (Dyneon), Solvay S.A. (Tecnoflon), HaloPolymer (Elaftor), Gujarat Fluorochemicals (Fluonox), and several Chinese manufacturers. Fluoroelastomers are more expensive than neoprene or nitrile rubber elastomers. They provide additional heat and chemical resistance. FKMs can be divided into different classes on the basis of either their chemical composition, their fluorine content, or their cross-linking mechanism.
Ethylene propylene rubber is a type of synthetic elastomer that is closely related to EPDM rubber. Since introduction in the 1960s, annual production has increased to 870,000 metric tons.
Membrane roofing is a type of roofing system for buildings, RV's, Ponds and in some cases tanks. It is used to create a watertight covering to protect the interior of a building. Membrane roofs are most commonly made from synthetic rubber, thermoplastic, or modified bitumen. Membrane roofs are most commonly used in commercial application, though they are becoming increasingly common in residential application.
Thermoplastic vulcanizates (TPV) are dynamically vulcanized alloys consisting mostly of fully cured EPDM rubber particles encapsulated in a polypropylene (PP) matrix. They are part of the thermoplastic elastomer (TPE) family of polymers but are closest in elastomeric properties to EPDM thermoset rubber, combining the characteristics of vulcanized rubber with the processing properties of thermoplastics. There are almost 100 grades in the S portfolio that are used globally in the automotive, household appliance, electrical, construction, and healthcare markets. The name Santoprene was trademarked in 1977 by Monsanto, and the trademark is now owned by Celanese. Similar material is available from Elastron and others.
Micronized rubber powder (MRP) is classified as fine, dry, powdered elastomeric crumb rubber in which a significant proportion of particles are less than 100 µm and free of foreign particulates. MRP particle size distributions typically range from 180 µm to 10 µm. Narrower distributions can be achieved depending on the classification technology.
Sulfur vulcanization is a chemical process for converting natural rubber or related polymers into materials of varying hardness, elasticity, and mechanical durability by heating them with sulfur or sulfur-containing compounds. Sulfur forms cross-linking bridges between sections of polymer chains which affects the mechanical and electronic properties. Many products are made with vulcanized rubber, including tires, shoe soles, hoses, and conveyor belts. The term vulcanization is derived from Vulcan, the Roman god of fire.
↑ Green, Mark M.; Wittcoff, Harold A. (July 2003). Organic Chemistry Principles and Industrial Practice. Weinheim, Germany: Wiley. p.170. ISBN978-3-527-30289-5. In addition to natural rubber, many synthetic rubbers... such as... ethylene-propylene-diene monomer rubber...
↑ Louie, Douglas K. (2005). "Elastomers". Handbook of sulphuric acid manufacturing. Richmond Hill, Canada: DKL Engineering, Inc. pp.16–116. ISBN978-0-9738992-0-7. EPDM (Ethylene Propylene Diene Monomer) is a M class Rubber containing a saturated chain of the polyethylene type.
↑ Winters, R.; Heinen, W.; Verbruggen, M. A. L.; Lugtenburg, J.; Van Duin, M.; De Groot, H. J. M. (2002). "Solid-State 13C NMR Study of Accelerated-Sulfur-Vulcanized 13C-Labeled ENB−EPDM". Macromolecules. 35 (5): 1958–1966. Bibcode:2002MaMol..35.1958W. doi:10.1021/ma001716h. hdl:1887/3239453.
↑ Traz Ouhadi; Sabet Abdou-Sabet; Hans-Georg Wussow; Larry M. Ryan; Lawrence Plummer; Franz Erich Baumann; Jörg Lohmar; Hans F. Vermeire; Frédéric L.G. Malet (2014). "Thermoplastic Elastomers". Ullmann's Encyclopedia of Industrial Chemistry. Weinheim: Wiley-VCH. pp.1–41. doi:10.1002/14356007.a26_633.pub4. ISBN978-3-527-30673-2.
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