Royal Elastomers Compounding Guide

1 0 Compounding Guide Liquid Natural rubber Liquid Synthetic rubber Liquid Low Molecular Weight Butyl rubber Royal Elastomers 600 Cortlandt Street, Belleville, NJ 07109 z Tel: (888) 442-7362 z Fax: (973) 751-8407 z Cross-Linked Butyl rubber GENERAL INFORMATION INTRODUCTION Royal Elastomers , LLC produces specialty rubber intermediates for adhesives, sealants, and rubber compounds. The family of specialty intermediates provides both specialty properties and improved processing in a wide range of applications. DPR Liquid Natural rubber . Performance additive for rubber Compounding . Reactive plasticizer processing aid for rubber Compounding . Reactive wetting agent for highly filled rubber compounds. Binder for grinding wheels, brake pads and other highly-filled, wear-resistant products. Rheology modifier for lubricants, oils, and asphalt systems.

2 ISOLENE Liquid Synthetic rubber . Reactive plasticizer for S-I-S block copolymers and pressure sensitive adhesives (PSA). Reactive vehicle for rubber additives and curatives. Performance additive and processing aid for rubber Compounding . KALENE Liquid Butyl rubber . Base polymer and performance additive for the manufacture of moisture resistant coatings, marine and construction sealants, electrical encapsulants, and pressure sensitive adhesives. KALAR Partially Cross-Linked Butyl rubber . Convenient pellets of cross-linked butyl rubber . Base polymer and performance additive for sealants, coatings, caulks, adhesives, butyl tapes, automotive windshield tapes and automobile sound dampening systems. APPLICATIONS DPR Liquid Natural rubber The DPR products are low molecular weight, liquid polymers of natural rubber .

3 DPR liquid rubber offers processing flexibility and performance options for a wide range of applications. They contain no solvents or additives; and they are compatible with a broad range of solvents, plasticizers, resins and polymers. DPR liquid natural rubber is available in several grades that vary by molecular weight. The lower weight grades have lower viscosity. Liquid natural rubber improves rubber and polymer Compounding . It acts as a plasticizer to reduce cycle time and energy consumption. Since it cures by the same mechanism as natural rubber , it becomes part of the polymer matrix and remains non-fugitive. Typical Applications DPR liquid rubber provides all the performance properties of natural rubber in a convenient liquid. Liquid rubber performs many functions in a wide range of applications: Binder for aggregates, grinding wheels, and friction products.

4 rubber processing aid. rubber performance improvement. Reactive vehicle for rubber additives. Rheology modifier for lubricants. Polymer base for molding and tooling systems. Polymer base for electrical encapsulants. Asphalt modifier. DPR liquid rubber has excellent wetting characteristics. It binds synthetic fibers and other reinforcements into polymer matrices. DPR can bind more than ten times its weight in fillers and abrasives for grinding wheels and other friction products. DPR reduces the viscosity of uncured rubber systems at levels of 5-to-20 parts of polymer. This reduces power requirements, improves blend consistency, and reduces the risk of scorching. It is also used with such polymers as polychloroprene, EPDM, polybutadiene, SBR and acrylonitrile-isoprene. DPR liquid rubber improves the stability of heavy-duty lubricants by increasing the resistance to flow on vertical surfaces and by holding dry additives in a more stable suspension.

5 It also improves asphalt formulations by reducing flow at high temperatures and improving properties at cold temperatures. ISOLENE Liquid Synthetic rubber The ISOLENE products are low molecular weight, liquid polymers of synthetic rubber . They are translucent, honey-colored liquids in bulk volume and clear in thin films. The color and clarity are ideal for pressure sensitive adhesives (PSA), UV curable polymer systems, and S-I-S and S-B-S block copolymer Compounding . The ISOLENE products improve adhesive and polymer Compounding . They act as plasticizers to reduce cycle time and energy consumption. They cure into the polymer matrix and remain non-fugitive in the final product. ISOLENE polymers are available in two commercial grades The regular ISOLENE polymer and the ISOLENE S-Grades.

6 The S-Grades contain an antioxidant to improve the long-term color stability. Both grades come in two standard viscosities. Typical Applications The light colored ISOLENE products are ideal for Compounding PSA. The low molecular weight liquid polymers 1 are reactive plasticizers that improve several adhesive attributes: Impart green tack. Maintain adhesion at low temperatures. Improve coating and flow characteristics. Improve adhesion to flexible substrates. Avoid bleed-through associated with other plasticizers. The ISOLENE products improve the solubility of polymers in the adhesive. They reduce the required energy and time to compound S-I-S pressure sensitive adhesives. ISOLENE products can soften hot melt adhesives and lower their melt temperature. ISOLENE polymers form the base polymer in such UV-cured systems as PSA, flexible printing plates, and other radiation cured systems.

7 KALENE Liquid Butyl rubber The KALENE products are low-molecular-weight liquid polymers of butyl rubber and no solvents. They provide gas impermeability, chemical resistance, moisture resistance, and good electrical properties. Typical Applications The KALENE products impart the performance benefits of butyl rubber and provide the processing convenience of a liquid. They make convenient bases for sealants, coatings, and adhesives. These coatings have higher solids than those based on butyl rubber because the KALENE products are liquids. KALENE s butyl properties impart chemical resistance to a wide variety of sealants and adhesives. Underwater marine and roof coatings take advantage of the resistance to salt and fresh water. Such applications as tank linings and coatings utilize the chemical and moisture resistant properties.

8 The KALENE products provide tack to pressure sensitive adhesives and they improve the adhesion of butyl-based adhesives and sealants. They also act as reactive plasticizers for conventional butyl to improve Compounding efficiency. Since they cure by the same mechanism as butyl rubber , they become part of the polymer matrix. They are non-fugitive. KALAR Cross-Linked Butyl Pellets The KALAR products are partially cross-linked butyl rubber compounds. They are pellitized for easy handling. They feature the performance benefits of butyl rubber , the processing ease of pellets, and the ability to maintain their properties with a high level of fillers and plasticizers. They also impart excellent resistance to creep and flow. The KALAR products provide act as the base polymer or as a performance additive for adhesives and sealants that require the properties of butyl rubber .

9 These benefits include excellent chemical resistance, moisture & gas impermeability, good electrical properties and resistance to aging. The KALAR products offer several processing benefits to formulators of butyl systems: Eliminates butyl rubber premastication. Requires no vulcanization. Dissolves easily in a wide range of solvents. Extends with high levels of fillers and plasiticizers. Blends readily with other Compounding ingredients. Typical Applications The principal applications for KALAR cross-linked butyl are as sealants for commercial and industrial markets: Industrial sealant tape. Architectural glazing tape. Automotive windshield tape. Automotive sealant and sound deadening compound. Tire sealant. High-strength thermoplastic sealant. Weather-proofing sealant tape. KALAR products impart the benefits of butyl rubber to many other applications.

10 These applications incorporate KALAR products in concentrations that range from a few percent to the major part of the formulation: Hot-melt glazing compounds. Solvent release coatings. Caulks. Construction adhesives. Tank linings and roof coatings. The processing advantages make the KALAR products a convenient tool for compounders. They use KALAR products in small concentrations in conventional systems: Processing aid for butyl rubber . Enhance green strength in butyl and EPDM compounds. PACKAGING, HANDLING AND PROCESSING DPR and ISOLENE Both of these products are packaged in open-head drums. All grades may be charged directly from container to the appropriate mixing vessel DPR and ISOLENE likewise may be stored at elevated temperatures, which do not exceed 60 C. This pre-heating may be done for several days prior to use.