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1816 | Soft Matter, 2014, 10, 18161822 This journal is The Royal Society of Chemistry 2014
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similar to the available size of the broken EPDM droplets before Table 2 Composition of premix for use in Haake rheomix
coalescence in an unvulcanized EPDM/PP blend.
Ingredient Content of the ingredients
Therefore, in the present work, the minimum size of the
(wt%)
broken rubber particles in the EPDM/PP blend was rstly
calculated by using the formula about the critical breakup EPDM 59.4
condition of the viscoelastic droplets in a viscoelastic matrix, as PP 39.6
proposed by Wu.29 Meanwhile, the actual size of the rubber 1010 0.15
Resol 0.7
particles in TPV at both the early stage and the nal stage of SnCl2 0.15
dynamic vulcanization was observed by using a new kind of
peak force tapping atomic force microscopy (PF-AFM) for its
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PP 0.5 159
EPDM 66 61
a
At 230 C and 2.16 kg. MFI melt ow index; Tm melting point.
This journal is The Royal Society of Chemistry 2014 Soft Matter, 2014, 10, 18161822 | 1817
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tome (Leica EM UC7; Germany). In order to observe the size and Therefore, the minimum diameter (amin) of the rubber phase
shape of the individual rubber particles, we dissolved the in the EPDM/PP blend at the early stage of dynamic vulcaniza-
dynamically vulcanized TPV in hot xylene for 96 hours and tion can be estimated by using the critical breakup law of the
refreshed the solvent every 24 hours to wash o the dissolved dispersed droplets in an immiscible blend proposed by Wu as
PP. The suspension obtained was then spin coated on a clean follows:29
coverslip by using a spin coater (KW-4A; China). The sample :
obtained was observed by the PF-AFM as well. The rubber ghm 1 1
4 sin2f $ g12 (3)
particle size was determined with the Image-Pro Plus 4.5 Fp L B
soware.32
16p 16
F p (4)
19p 16
3 Results and discussion where g_ is the shear rate, hm is the viscosity of the matrix, p
3.1 Theoretical calculation of critical size of rubber phase in is the viscosity ratio of droplet to matrix (hd and hm), F is the
the matrix angle between the major axis of the deformed ellipsoid droplet
The breakup of the rubber phase in EPDM/PP TPV occurs when and the axis perpendicular to the ow direction (see Fig. 1), and
the premix is just fed into the Haake rheomix.13,19 Because of its g12 is the interfacial tension between the droplet and the
extremely low crosslink density, the deformation and breakup matrix.
of the rubber phase at this time can be approximated by those of As hm, p, L/B, g,_ g12, and sin(2F) can be obtained from
unvulcanized EPDM in EPDM/PP blend in a rotational shear experimental results, the minimum value of a(amin) can thus be
eld. For an immiscible polymer blend such as unvulcanized calculated according to eqn (2)(4).
EPDM/PP blend, the minimum size of the EPDM dispersed The temperature at which the rubber phase in the EPDM/PP
phase can be obtained from the critical breakup law proposed blend breaks up should be determined to calculate the value of
by Wu.29 The precondition for the breakup of an EPDM spher- amin because the values of hm, p, and g12 depend on the
ical viscoelastic droplet with initial diameter a is that the temperature. As will be interpreted in detail in Section 3.2, the
droplet is rst stretched under a rotational shear eld to be an temperature at the early stage of dynamic vulcanization was set
ellipsoid droplet with the major semi axis L and short semi axis as 170 C, at which the blend was melted. Therefore, 170 C was
B, as shown in Fig. 1. The breakup of an EPDM viscoelastic chosen as the temperature to calculate amin in the EPDM/PP
droplet continues until its diameter (a) reaches a critical value blends.
(amin), at which the droplet cannot break up any more but 3.1.1 Determination of g. _ The shear rate in the Haake
deforms to be an ellipsoid.29 As the volume of the deformed rheomix is not a constant value because of the dierent diam-
droplet is constant in the rotational shear eld, the volume of eters at dierent positions of the rotors. According to the
the spherical droplet is identical to the volume of the ellipsoid parameters provided by the manufacturer (Thermo Fisher
droplet, as shown in the following equation: Scientic), the shear rate in the Haake rheomix ranges from 7
s1 to 108 s1 at a rotor speed of 80 rpm.
3.1.2 Determinations of hm and p. The viscosities of EPDM
and PP at 170 C as a function of shear rate were measured by
using the rotational rheometer. Fig. 2 shows the measured
viscosities of the uncured EPDM (hd) and PP (hm). The loga-
rithmic plots for both PP and EPDM are approximately linear. It
can be seen that the shear rate has a signicant eect on the
viscosity of a viscoelastic liquid. The values of hd and hm at
dierent shear rates can be obtained from this gure. Addi-
tionally, the corresponding p and F(p) values can also be
obtained.
3.1.3 Determination of g12. The interfacial tension (g12)
between PP and EPDM can be obtained from the well-known
Fig. 1 Droplet deformation in uniform shear. harmonic mean in eqn (5).29
1818 | Soft Matter, 2014, 10, 18161822 This journal is The Royal Society of Chemistry 2014
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Fig. 2 Viscosity vs. shear rate for uncured EPDM and PP at 170 C.
4gd1 gd2 4gp1 gp2 EPDM/PP blend is always micrometer scale because of the
g12 g1 g2 (5) coalescence of EPDM droplets aer the shear has stopped.34 For
gd1 gd2 gp1 gp2
the vulcanized EPDM/PP blend at the early stage of dynamic
where g1 and g2 denote the surface tensions (g) of EPDM and vulcanization, the rapid crosslinking of the EPDM phase could
PP, respectively, and gd and gp are the associated nonpolar and eectively stop the coalescence of EPDM droplets. Therefore,
polar components of g respectively.13 The gd and gp values of theoretically speaking, the minimum size of the EPDM phase in
EPDM and PP at high temperatures cannot be measured the vulcanized EPDM/PP blend could be the same as that of an
directly, but calculated from the c values of EPDM and PP. The EPDM droplet in the unvulcanized EPDM/PP blend because of
c value is the ratio of the polar component to the total surface the in situ vulcanization of the EPDM phase. Thus, the EPDM
tension and is independent of temperature:13 phase in the dynamically vulcanized EPDM/PP blend could
gp break up into rubber nanoparticles at the early stage of dynamic
c (6)
g vulcanization.
dc
0 (7) 3.2 Experimental verication: morphology observation
dT
In order to observe the actual size of the rubber phase in the
Table 3 lists the measured c, g, and the calculated gd and gp dynamically vulcanized EPDM/PP blend at the early stage of
values of EPDM and PP at 170 C. According to these values dynamic vulcanization, we need to rst select the sample
listed in Table 3, the interfacial tension (g12) between unvul- according to the torquetime curve. Fig. 3 shows the variation of
canized EPDM and PP at the early stage of vulcanization can be
the mixing torque and temperature as a function of time during
calculated as 5.3 mN m1.
the dynamic vulcanization of the EPDM/PP blend in the Haake
3.1.4 Determination of sin(2F). According to eqn (2) and
rheomix. At the initial stage, the mixing torque decreases with
the results reported by Grace,33 the relation between a and L can the increase in mixing time because of the melting of the blend.
be obtained when the p value is determined. In addition, the Sample A is selected at the inection point A, where the torque
droplet deformation is large in our system. In this case, the reaches a minimum, because the blend has just melted at
value of a/2L is very close to the value of cos F, as can be seen this point. Thus, sample A represents the EPDM/PP blend at the
from Fig. 1. Thus, the value of sin(2F) can be obtained from the early stage of vulcanization. With the rapid vulcanization of the
calculated value of cos F.
rubber phase, the torque rises dramatically until it reaches a
3.1.5 Calculation of amin. According to these measured
maximum before declining slowly until the end of dynamic
_ in the range of 7.1
values of hm, p, and g12 at each shear rate (g)
vulcanization. On the other hand, the temperature increases as
s1 to 108 s1, the minimum diameter of the dispersed EPDM the premix is fed into the Haake rheomix because of the
droplet (amin) is calculated by using eqn (2)(4) and is shown in crosslinking of EPDM. The temperature corresponding to point
Table 4. It can be seen that amin ranges from 2546 nm.
The calculated results indicate that the EPDM phase in the
unvulcanized EPDM/PP blend can break up into rubber nano- Table 4 Measured parameter values and calculated values of amin
scale droplets. However, the EPDM phase in the unvulcanized
g_ hd hm F(p) L/B a/2L sin(2F) amin
(s1) (Pa s) (Pa s) (nm)
Table 3 Surface tension and its components for uncured EPDM and
PP at 170 C 7 4.4 104 3.3 104 0.903 7.70 0.249 0.482 46
20 3.0 104 1.7 104 0.893 9.26 0.220 0.430 37
Material c g gd gp 30 2.8 104 1.6 104 0.894 9.53 0.218 0.426 26
(mN m1) (mN m1) (mN m1) 50 2.3 104 1.2 104 0.890 11.50 0.188 0.369 25
70 1.9 104 9.5 103 0.888 13.71 0.169 0.332 25
EPDM 0.12 23.08 20.31 2.77 90 1.7 104 8.0 103 0.886 14.50 0.168 0.331 26
PP 0.35 32.67 21.24 11.43 108 1.2 104 5.2 103 0.884 15.67 0.170 0.315 35
This journal is The Royal Society of Chemistry 2014 Soft Matter, 2014, 10, 18161822 | 1819
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1820 | Soft Matter, 2014, 10, 18161822 This journal is The Royal Society of Chemistry 2014
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3.3 Formation mechanism of rubber nanoparticles and their phase (sea island structure). In addition, these agglomerates
agglomerates during dynamic vulcanization become much denser than those at the early stage of dynamic
vulcanization because of the increased interfacial energy caused
Fig. 7 shows the formation mechanism of rubber nanoparticles
by the increase in crosslink density and modulus of EPDM
and their agglomerates during dynamic vulcanization. The
particles. Based on the mechanism, we can control the diameter
breakup of the EPDM phase at the early stage of dynamic
of rubber nanoparticles and their agglomerates through
vulcanization is similar to that of the unvulcanized EPDM in
controlling the components of TPV as well as the processing
the EPDM/PP blends because of the low crosslink density of the
conditions. This study provides guidance for controlling the
EPDM phase at the early stage of dynamic vulcanization. In the
size of the rubber phase in TPV to prepare high performance
unvulcanized EPDM/PP immiscible blend, the breakup and
TPV products.
coalescence of the EPDM phase occur simultaneously in the
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1822 | Soft Matter, 2014, 10, 18161822 This journal is The Royal Society of Chemistry 2014