Jianliang Jiang†
ab,
Junxue Zhai†c,
Lingxin Kongc,
Dongqi Zhaod and
Yakai Feng*ab
aSchool of Chemical Engineering and Technology, Frontiers Science Center for Synthetic Biology, Key Laboratory of Systems Bioengineering (Ministry of Education), Tianjin University, Yaguan Road 135, Tianjin 300350, China. E-mail: yakaifeng@tju.edu.cn
bFrontiers Science Center for Synthetic Biology, Key Laboratory of Systems Bioengineering (Ministry of Education), Tianjin University, Yaguan Road 135, Tianjin 300350, China
cKey Laboratory of Rubber-Plastics of Ministry of Education/Shandong Province, School of Polymer Science & Engineering, Qingdao University of Science & Technology, 5 Zhengzhou Road, Qingdao 266042, China
dTianjin Joaboa Technology Co., Ltd, No. 24 Road, Tianjin 301609, P. R. China
First published on 28th September 2022
The tensile strength and elongation at break of rubbers are mutually restrictive factors. Design and preparation of chloroprene rubber (CR) with high tensile strength, high elongation at break and excellent flame retardancy at the same time is challenging. Melamine cyanurate (MCA) is for the first time discovered to be a reactive flame retardant for CR. The tensile strength of C-M36 (with 3 wt% ZnO and 36 wt% MCA) vulcanizate is 2.5 times that of C-M0 (only with 3 wt% ZnO) vulcanizate, while the elongation at break of C-M36 vulcanizate is 1.3 times that of ZnO cross-linked C-M0 vulcanizate. At the same time, the limiting oxygen index of C-M36 (39%) is 1.22 times that of C-M0 (32%). FTIR and the vulcanization tests confirm that the reaction between CR and cyanuric acid occurs under the catalysis of a base (melamine), and the cyanuric acid molecules are grafted onto the molecular chain of CR. Two types of crosslinking networks are formed in CR vulcanizate, namely the traditional covalent bond crosslinks and the triple hydrogen crosslinks formed between cyanuric acid and melamine. Thus, the flame-retardant CR/MCA vulcanizate with high strength and high elongation at break is obtained. This research will strongly promote the industrial application of CR.
The ever-increasing demand for energy consumption and the pollution from energy access have put more pressure on the entire human society.14–17 The traditional rubber vulcanization method consumes a lot of energy, and the vulcanization process is not friendly to the environment. Therefore, the green vulcanization method of rubber has become a research hotspot. ZnO/MgO particles were frequently used as CR vulcanizing agents,6 as their vulcanization process has the advantages of low energy consumption, light environmental pollution, and little harm to operators. Tripathy et al.18 proposed a vulcanization reaction mechanism between CR and MgO. Two CC–C–Cl groups of CR react with MgO to form a CC–C–O–C–CC bond and MgCl2. Peter Kovacic discovered the crosslinking reaction between CR and piperazine with elimination of hydrogen chloride.19 Moreover, the use of lead oxide was also reported for vulcanization, however, due to the environmental pollution of lead elements, this vulcanization method was rarely used in the industrial application of CR. Imidazole compounds were also reported in patents, but the mechanism of their vulcanization reaction of CR is not very clear.20 The chlorine atom in the CR polymer chain makes the reactivity of the CC bond and the carbon atom connected to the CC bond (CC–C–X, hydrogen or chlorine) different from that of the traditional rubber. Therefore, the traditional sulfur vulcanization method cannot vulcanize CR very well.9
Most of the crosslinks obtained by the existing CR vulcanization methods are covalent bonds, and the tensile strength and elongation at break of CR cannot be simultaneously improved. The dynamic bond crosslinking of rubber to achieve the simultaneous improvement of the tensile properties and elongation at break of the material has been reported in the literature.21–24 Chen et al.25 found that the tensile strength and elongation at break of PBMs cross-linked by dynamic bond (Fe2+–pyrazine) were 2 times and 23 times higher than those of PBMs cross-linked by covalent bonds. Xie et al.26 introduced Fe3+–COOH coordination bonds into the hydrogel network of polyacrylic acid to form a double network structure and also achieved a significant improvement in the strength and elongation at break of the hydrogel. Inspired by the above literature, the primary goal of this paper is to find a dynamic crosslinking method for CR.
Melamine cyanurate (MCA) is a kind of green and environmentally friendly flame-retardant and its application in plastics has received more and more attention.27–30 MCA is very stable within 300 °C, and decomposes above 600 °C.31 Moreover, MCA is a nitrogen-based, intumescent flame retardant. The vulcanizate added with MCA has excellent flame-retardant properties, and low smoke density during combustion and rarely produces toxic and corrosive gases.32–34 Traditionally, MCA is generally added to materials as an additive flame retardant. In the early exploratory test, we unexpectedly found that after the addition of MCA in CR, the vulcanization rate slowed down and the mechanical properties of the CR vulcanizate also changed significantly. After the detailed study, it was found that MCA could react with CR to form a network structure of dynamic bond crosslinking. Surprisingly, after adding zinc oxide and MCA to CR, with the addition of zinc oxide and MCA to CR, both covalent bonds and dynamic chemical bonds were formed in CR vulcanizate. Excitingly, the tensile strength and elongation at break of CR vulcanizate were improved at the same time and the flame retardancy of CR has also been significantly improved. In this work, we inadvertently discovered a new dynamic crosslinking method for CR, which provides a new strategy for the improvement of CR performance.
The blend designations and compositions are shown in Table 1.
Ingredient (phr) | Sample ID | |||||
---|---|---|---|---|---|---|
C-M0 | C-M3 | C-M6 | C-M12 | C-M24 | C-M36 | |
CR | 100 | 100 | 100 | 100 | 100 | 100 |
ZnO | 3 | 3 | 3 | 3 | 3 | 3 |
MCA | 0 | 3 | 6 | 12 | 24 | 36 |
Stearic acid | 1 | 1 | 1 | 1 | 1 | 1 |
The tensile properties of the samples were tested according to GB/T 528-2009 using a GT-AI-7000-S high temperature stretching machine with a speed of 500 mm min−1, at 30 °C and 180 °C, respectively. The average value of three individual samples was recorded for each sample.
ATR-FTIR spectra were recorded on a VERTEX70 spectrometer. Samples were characterized by signal averaging 32 scans at a resolution of 4 cm−1 in the wavenumber range of 500–4000 cm−1.
The friction coefficient of the samples was tested by the GT-7012-AF tester and the static and dynamic friction coefficients of the vulcanized rubber on the glass surface were determined according to GB/T 10006-2021. The average value of three individual samples was recorded for each sample.
The high-temperature aging tests were carried out in a GT-7017-E incubator and the aging condition was 200 °C × 2 h.
The limiting oxygen index of the samples were tested by HC-2 oxygen index tester. The tests were carried out according to the method of GB/T 2406.2-2009.
Test items | Sample ID | |||||
---|---|---|---|---|---|---|
C-M0 | C-M3 | C-M6 | C-M12 | C-M24 | C-M36 | |
T10/min | 0.64 | 0.70 | 0.66 | 0.62 | 0.61 | 0.63 |
T90/min | 8.40 | 10.25 | 10.75 | 11.30 | 13.02 | 16.03 |
ML/dN m | 0.36 | 0.42 | 0.46 | 0.48 | 0.56 | 0.62 |
MH/dN m | 6.13 | 6.30 | 6.52 | 7.50 | 8.67 | 10.06 |
As shown in Table 2 and Fig. 1, with the increase of MCA content, the minimum torque (ML) increases slowly, but the maximum torque (MH) increases significantly. The MH of C-M36 is 1.64 times that of C-M0. It is generally believed that the value of MH is positively related to the crosslinking density of rubber, so we can infer that MCA has indeed involved in the crosslinking reaction with CR.
MCA is formed by self-assembly of melamine and cyanuric acid through intermolecular hydrogen bond interactions (amino and carbonyl) and has a stable supramolecular structure (Fig. 2).35 Under the catalysis of organic bases, the reaction of the N–H of cyanuric acid with C–Cl bond of small molecules can take place with a good yield (>90%), which has been reported in the literature.36,37 The melting point of MCA is close to 350 °C, which is much higher than the vulcanization temperature of CR. During the vulcanization at 170 °C, the reaction between MCA and CR is heterogeneous (solid–liquid reaction). It can be speculated that a nucleophilic substitution reaction between the N–H group of the cyanuric acid (located at the interface of MCA crystal) and C–Cl bond of CR occurs under alkali catalysis (melamine), but the other two N–H groups of one cyanuric acid inside the MCA crystal could not react with the C–Cl bond of CR (Fig. 2), because of their triple hydrogen bonding. Therefore, a possible crosslinking reaction between CR and MCA is proposed (Fig. 3).
Fig. 3 Possible reactions between MCA and CR (inside the red ellipse, melamine molecules are confined to the surface of the MCA crystal). |
The CO absorption band of free cyanuric acid is exhibited at 1690 cm−1.39,40 Due to the triple hydrogen bonds between cyanuric acid and melamine, the CO absorption band of MCA and CR/MCA is shifted to high wavenumber at 1778 cm−1 and 1731 cm−1, respectively. This is due to the increase in stiffness of CO arising from the formation of hydrogen bonding between melamine and cyanuric acid.41,42 Unfortunately, only very small part of cyanuric acid (located at the edge of MCA crystal) could react with CR through nucleophilic substitution, which is difficult to be monitored by the intensity or shift of the carbonyl absorption peak.
The N–H absorption peak of free cyanuric acid is presented at 3427 cm−1, while the N–H absorption band of free melamine is presented at 3427 and 3472 cm−1.41,42 Because of the triple hydrogen bond, the N–H absorption band of MCA and CR/MCA was shifted to low wavenumber at 3374 and 3235 cm−1, respectively. Taking the C–H absorption peak at 2916 cm−1 of CR as the reference peak, the change of MCA content can be judged by the absorption peak height of N–H relative to that of C–H. As shown in Fig. 4c, the ATR-FTIR spectrum of CR/MCA vulcanizate shows the characteristic peaks of CR and MCA. Comparing with Fig. 4c and d, the absorption peak intensities of CR/MCA are higher than those calculated by content, the possible reason is that CR promotes the dispersion of MCA powder during the mixing and vulcanization process. The particle size becomes smaller and the interface area increases. Therefore, the number of N–H on the MCA crystal interface increases.
Comparing with Fig. 4c and e, it can be found that the intensity of the N–H stretching vibration absorption peaks at 3374 cm−1, 3235 cm−1 of CR/MCA vulcanizate further decreases after aging, while the absorption peak intensity of C–H bond at 2916 cm−1 is basically unchanged, indicating the N–H bond of cyanuric acid can react with the C–Cl bond of CR under the catalysis of melamine. Herein, MCA acts as both a reactant and a catalyst.
The influence of grinding on the surface of CR/MCA vulcanizate was further investigated (using sandpaper, with a grinding thickness of about 0.5 mm). Comparing with Fig. 4e and f, the intensity of N–H absorption peaks at 3374 cm−1, 3235 cm−1 of CR/MCA vulcanizate after surface grinding is significantly higher than those of CR/MCA vulcanizate without surface grinding. The intensity of C–H absorption peak at 2916 cm−1 decreases significantly after surface grinding, because CR is easier to remove during the grinding process, the CR content decreases and the MCA content increases on the surface layer of the CR/MCA vulcanizate. This result is consistent with the results discussed in the CR friction coefficient section later.
Test items | Samples | |||||
---|---|---|---|---|---|---|
C-M0 | C-M3 | C-M6 | C-M12 | C-M24 | C-M36 | |
At 30 °C | ||||||
Tensile strength, MPa | 2.75 ± 0.21 | 1.64 ± 0.15 | 1.04 ± 0.13 | 5.24 ± 0.24 | 7.83 ± 0.26 | 6.79 ± 0.23 |
Elongation at break, % | 664 ± 43 | 542 ± 42 | 215 ± 34 | 1019 ± 76 | 570 ± 47 | 887 ± 63 |
Tensile strength at 25%, MPa | 0.25 ± 0.01 | 0.23 ± 0.01 | 0.40 ± 0.01 | 0.46 ± 0.01 | 0.65 ± 0.01 | 0.88 ± 0.01 |
Tensile strength at 100%, MPa | 0.53 ± 0.02 | 0.50 ± 0.01 | 0.68 ± 001 | 0.79 ± 0.01 | 1.05 ± 0.01 | 1.57 ± 0.02 |
Tensile strength at 300%, MPa | 0.79 ± 0.02 | 0.85 ± 0.02 | — | 1.19 ± 0.03 | 1.80 ± 0.04 | 2.38 ± 0.04 |
At 180 °C | ||||||
Tensile strength, MPa | 0.23 ± 0.01 | 0.44 ± 0.01 | 0.54 ± 0.02 | 0.70 ± 0.03 | 0.72 ± 0.03 | 0.74 ± 0.03 |
Elongation at break, % | 11 ± 1.2 | 54 ± 1.5 | 79 ± 2.1 | 100 ± 2.9 | 100 ± 2.8 | 95 ± 2.9 |
Tensile strength at 25%, MPa | — | 0.31 ± 0.01 | 0.33 ± 0.01 | 0.39 ± 0.01 | 0.41 ± 0.02 | 0.41 ± 0.01 |
Tensile strength at 100%, MPa | — | — | 0.15 ± 0.01 | 0.70 ± 0.02 | 0.63 ± 0.02 | — |
As shown in Table 3, the tensile strength of the C-Mx vulcanizate decreases significantly at high temperature. The tensile strength of C-Mx vulcanizate at 180 °C is 0.1–0.5 times that of C-Mx vulcanizate at 30 °C. Mainly because the force between the polymer chains of CR decreases with increasing temperature. The tensile strength of C-Mx vulcanizate increases with the increase of MCA content at 180 °C. The tensile strength of C-M36 vulcanizate is 3.2 times that of zinc oxide cross-linked C-M0 vulcanizate, while the elongation at break of C-M36 vulcanizates is 8.6 times that of zinc oxide cross-linked C-M0 vulcanizates.
For conventional vulcanizates, it is difficult to achieve simultaneous improvement in tensile strength and elongation at break. It can be seen from Table 3 that the tensile strength and elongation at break of the CR/MCA vulcanizate are both improved compared to the traditional zinc oxide vulcanized CR. During the stretching process, the triple H-bonding crosslinks in the CR/MCA vulcanizate play an important role in the stretching process. The crosslinking bonds of zinc oxide vulcanized CR are covalent bonds. Due to the uneven distribution of covalent bond crosslinks, the covalent crosslinking bonds at the stress concentration point are broken firstly, and the tensile strength and elongation at break cannot be increased at the same time (Fig. 5a). The CR/MCA vulcanizate contains both covalent crosslink bonds and triple hydrogen bond crosslinks. During the stretching process, the triple H-bonding crosslinks are first broken, which is conducive to the adjustment of the configuration of the CR molecular chains along the stretching direction. The generation of cyanuric acid on the side chain of the CR molecule can simultaneously form new triple H-bonding crosslinks with other nearby MCAs, thereby significantly improving the tensile strength and elongation at break of the CR/MCA vulcanizate (Fig. 5b). The tensile strength and elongation at break of CR/MCA vulcanizates at 180 °C are more significantly improved than those of CR/MCA vulcanizates at 30 °C. Probably because the high temperature is more conducive to the dissociation and recombination of triple H-bonding.
Fig. 5 Schematic diagram of the tensile mechanism of single-network and double-network cross-linked CR. (a) Covalent bond network, (b) double crosslinked network. |
The median and average data of the dynamic coefficient of friction and static coefficient of friction (SCOF) of CR/MCA vulcanizate are shown in Table 4. With the increase of MCA content, both the dynamic friction coefficient and the static friction coefficient gradually decreased, indicating that MCA can effectively reduce the friction coefficient of CR/MCA vulcanizate.
Test items | Sample | |||||
---|---|---|---|---|---|---|
C-M0 | C-M3 | C-M6 | C-M12 | C-M24 | C-M36 | |
Median date of SCOF | — | 4.10 ± 0.32 | 2.09 ± 0.23 | 2.46 ± 0.25 | 2.11 ± 0.23 | 1.75 ± 0.22 |
Average date of SCOF | — | 4.03 ± 0.34 | 2.12 ± 0.25 | 2.64 ± 0.22 | 2.11 ± 0.26 | 1.74 ± 0.21 |
Median date of DCOF | — | 1.66 ± 0.19 | 1.38 ± 0.15 | 1.52 ± 0.18 | 1.43 ± 0.17 | 1.37 ± 0.15 |
Average date of DCOF | — | 1.58 ± 0.17 | 1.39 ± 0.14 | 1.53 ± 0.13 | 1.43 ± 0.18 | 1.39 ± 0.16 |
The flame-retardant mechanism of MCA is related to the inert gas (diluted oxygen) generated by thermal decomposition, the generated expansion insulation layer and nitrogen oxides (to capture the free radicals and terminate the combustion reaction).43,44 It can be seen from Fig. 7, with the increase of MCA content, the LOI of CR/MCA vulcanizate continuously increases from 32 to 39, indicating that MCA (although MCA has reacted with CR) can effectively improve the flame retardancy of CR/MCA.
Footnote |
† Jianliang Jiang and Junxue Zhai contributed equally to this work. |
This journal is © The Royal Society of Chemistry 2022 |