Chapter 2 Materials and Methods Abstract The characteristics of all the materials used in the study and the details of the experimental techniques employed to get the final conclusion are presented in this chapter. The methods of preparation of both TPEs and TPVs are explained. The particulars of the analysis of phase morphology by scanning electron microscopy and atomic force microscopy are incorporated. The details of experimental setup and temperature programme for the spherulite growth of PP in presence of NR and NBR using polarising microscope coupled with hot-stage; the procedure for the study of bulk, fractionated and self seeding crystallization; and measuring the Wide–angle X-ray scattering (WAXS) pattern are included. Experimental setup for the isothermal and non- isothermal crystallization kinetics has been discussed in detail. Information about mechanical and dynamic mechanical tests, together with IR-strain measurements for NBR/PP TPVs and nano-indentation for the NR/PP TPEs are integrated.
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Chapter 2
Materials and Methods
Abstract
The characteristics of all the materials used in the study and the details of
the experimental techniques employed to get the final conclusion are presented
in this chapter. The methods of preparation of both TPEs and TPVs are
explained. The particulars of the analysis of phase morphology by scanning
electron microscopy and atomic force microscopy are incorporated. The
details of experimental setup and temperature programme for the spherulite
growth of PP in presence of NR and NBR using polarising microscope
coupled with hot-stage; the procedure for the study of bulk, fractionated and
self seeding crystallization; and measuring the Wide–angle X-ray scattering
(WAXS) pattern are included. Experimental setup for the isothermal and non-
isothermal crystallization kinetics has been discussed in detail. Information
about mechanical and dynamic mechanical tests, together with IR-strain
measurements for NBR/PP TPVs and nano-indentation for the NR/PP TPEs
are integrated.
88 Chapter 2
2. Experimental
2.1. Materials
Isotactic polypropylene, PP, (Koylene M3060) having melt flow index
(MFI) of 3g/10 min and density 0.905gm/cm3 at 23°C was kindly supplied by
Indian Petro Chemical Ltd, Vadodara, India. Natural rubber (NR, ISNR-5) and
epoxydised natural rubber (ENR25) were supplied by RRII, Kottayam, India.
Acrylonitrile co-butadiene rubber (Chemaprene N 3309) with acrylonitrile
content 34% was supplied by Synthetic and Chemicals, Bareli UP, India.
Hydroxy terminated natural rubber was synthesized in SCS, MGU. Exxon,
Germany provided the commercially available maleic anhydride
functionalized polypropylene, ExxelorTM PO 1020 with 0.5-1 wt% MA
content. Carboxylated polypropylene and NBR-MAPP graft copolymer
prepared from MA-PP and amine terminated NBR, (Hycar, Bayer, Germany)
were used for the compatibilization.
2.2. Methods: Melt Blending
NR/PP blends were prepared by melt mixing PP with NR in a Rheocord
at 180oC and 60 rpm. For the dynamic vulcanization, sulphur based curatives
were added to the blend in the mixing chamber where the vulcanization is
completed in 10 minutes.
NR/PP blends for the fractionated crystallization analysis, were prepared
by melt mixing PP with masticated NR in a Rheocord at 190°C and 60 rev/min
and to avoid the coalescence phenomena of the dispersed iPP phase, sulphur
based cure system was loaded in the blend using a two-roll mill and
vulcanized at 150°C (static vulcanization).
Materials and Methods 89
For the preparation of NBR/PP blends initially the components were
melt mixed in a Brabender Plasticoder PL 2000 at 65rev. min-1at 190°C for 4
min.
NBR/PP blends for the fractionated crystallization analysis, were
prepared by melt mixing PP with NBR in a Brabender Plasticoder at
65rev/min at 190°C for a mixing time of 6min and NBR phase was vulcanized
using sulphur based cure system. The compatibilizer were prepared at 180°C,
in the same brabender plasticoder, initially the MA-PP was melted and then low
molecular weight liquid NBR (Hycar ATBN X 16) is added and mixing
completed within 6min.
The compatibilizer were prepared at 180°C, in the same Brabender
Plasticoder. Initially the MA-PP had been melted and then low molecular
weight liquid NBR (Hycar ATBN X 16) is added and the mixing completed
within 6min.
For the preparation of dynamic vulcanizates initially the components
were melt mixed in a Brabender Plasticoder PL 2000 at 65rev. min-1 at 190°C.
Compatibilizer, curing agent and other additives were added following the
time-torque curve given in the fig 2.1. with the help of a computer attached to
the brabender. In Fig. 2.1, I, II, III and IV indicate order addition of each
additive and the corresponding time. (I-iPP, II-NBR, III-Compatibilizer, IV-
ZnO and Stearic Acid, V-Curing Agent, VI-Atioxidant) Mixing time was fixed
for 15min.
90 Chapter 2
0 2 4 6 8 10 12 14 160
2
4
6
8
10
12
14
16
18
VI
VIII
II
I
IV
Torq
ue (N
m)
Time (min)
Figure 2.1. Torque development during the dynamic vulcanization as a function of time.
Samples were hot pressed at 190°C under 70-bar pressure in a hydraulic
press. It is clear from the graph that at first the torque is high as we introduce
the iPP, when the temperature of the sample increases torque comes down.
Again it increases with the addition of NBR, and then the torque again comes
down. The compatibilizer is added and mixing continues till the torque levels
off. Then stearic acid and ZnO are added. After sometime torque again levels
off. Addition of curing agent leads to a substantial increase in the torque due
to the cross-linking of the rubber phase and thereby exerting grater resistance
to rotation. Thus the progress of the vulcanization can be conveniently
followed by monitoring torque during the mixing.
Materials and Methods 91
2.3. Analytical methods
2.3.1. Morphological characterization
The morphology of the NR/PP and NBR/PP blend was analyzed by
electron microscopy, using a SEM Philips microscope on cryogenically
fractured surfaces of the samples. Before the electron microscopy observation,
the surfaces were coated with Au–Pd alloy with a SEM coating device (SEM
Coating Unit). The SEM samples were prepared as follows: the strips cut from
compression-moulded samples were fractured in liquid nitrogen. NR and NBR
phases were removed by benzene and chloroform respectively. After etching
the phases, samples were dried in a vacuum oven at 70°C for 12 h and were
coated with gold using sputter coater. Then their SEM micrographs were
taken.
For the uncompatibilized and compatibilized blends micrographs were
obtained with average numbers and volume diameters (dn, dw and dv) of the
dispersed domains, using Image analysis software. The dispersity (D) of the
sizes obtained and the average number of particles/cm3 were also calculated
using the following equations.
dn = ∑ ∑ iii ndn / (2.1)
dw = iiii dndn∑ ∑/2 (2.2)
dv = iiii dndn 34 /∑ ∑ (2.3)
where ni is the number of droplets of ‘i’ with diameter di.
The polydispersity was evaluated with the equation D = dv/ dn
92 Chapter 2
The volume fraction of the dispersed phase was calculated from the following
relationship
Xv = (Xp/ρd)/[Xp/ρd+(1-Xp)/ρm] (2.4)
where Xp is the weight fraction of the minor phase and ρd is the dispersed
phase density.
The average particle number per cm3 was determined from
Nn = Xv 1cm3/[π/6(dn)3] (2.5)
The values calculated from the above equations could be used for
explaining the action of compatibilizer.
Atomic force microscopic examinations of the NBR/PP TPVs were
done using cryo-cut specimen with liquid nitrogen cooled diamond cutter.
Measurements were carried out in air at ambient conditions (25°C) with a
Nanoscope III Atomic Force Microscope, made by Digital Instruments Inc.,
USA. The experiments were carried out in tapping mode with constant
amplitude, using micro fabricated cantilevers. The scanning was done using
Olympus – Tapping Mode Etched Silicon Probe with square pyramid in shape.
The characteristics of the probe are: Force constant (K), 42 N/m; Nominal tip
radius of curvature less than 10 nm; cantilever length having a length of 160
µm and a tip height of 10 µm. Cantilever configuration: Rectangular Substrate
fits standard cantilever holder; Reflective coating with Aluminium; Tip half
angle of 17° on each side, 0° on front and 35° back. Images were analysed