New Developments in Properties for Ethylene Acrylate Polymers

18 Rubber & Plastics News • November 30, 2020 www.rubbernews.com www.rubbernews.com Technical Technical New developments in properties for ethylene acrylate polymers By Patricia Panne, Klaus Kammerer, Serge Bouvier, Ed McBride, Mark Stewart, Steve Oriani and Elias Wang Executive summary DuPont Vamac-brand ethylene acrylic elastomer (AEM) was introduced in 1975 and has been used successfully for many years in the Ethylene acrylate (AEM) polymers transportation sector, where excellent resistance to heat, engine fluids and low temperature flexibility is required. were first introduced to the elastomer With the introduction of the Vamac Ultra grades, a step-change improvement in processability, performance and customer value market more than 40 years ago. They for targeted applications has been achieved. Increasing demands for improved temperature stability led recently to the development are non-crystalline copolymers of eth- of the VMX5000 series of pre-compounds to offer compounds in applications with a 10-15°C higher heat resistance over conventional ylene and methyl acrylate. carbon black-filled AEM compounds. Resistance to engine oils and acids remains excellent, which makes the VMX5000 pre-com- Both monomers add to the high tem- pounds an interesting cost-effective alternative to FKM materials in the temperature range between -35°C and +175°C. perature stability, and the completely sat- For dynamic hose applications, slow-curing polymers (Vamac GXF, Ultra HT and HT-OR) have been introduced. While com- urated polymer chain imparts excellent pounds using the Ultra grades offer better physical properties, they sometimes lead to high extrusion pressure and therefore re- resistance to ozone, oxidation and weath- quire lower hardness compounds (<70 ShA). To offer more compounding flexibility and allow for cost savings, an intermediate ering. The non-polar ethylene contributes viscosity grade called Vamac Ultra XF has been developed that still allows extrusion of 70-75 ShA compounds with superior green to the good low-temperature flexibility strength and physical properties compared to Vamac GXF. while the polar methyl acrylate monomer More stringent safety requirements within the transportation and building sector continue to push for halogen-free, low-toxic- provides the oil and fluid resistance. ity materials. Vamac elastomers are halogen-free polymers and present an interesting option of material when low flammability, toxicity and smoke density combined with heat and fluid resistance are critical. Different starting point formulations have been TECHNICAL NOTEBOOK developed to show the range of HFFR material performance that can be obtained with Vamac. Edited by John Dick are used. For ducts and hoses, often ex- Sealing applications with in- based on three industry-accepted crite- Most of the polymer grades contain a trusion processes are used and slower creased temperature resistance ria: less than 50 percent loss in tensile small amount of acidic cure site monomer curing compounds with improved dy- Typical sealing applications for Va- strength and elongation at break, and for diamine crosslinking. Since the intro- namic properties are needed. mac are cam covers, oil pan gaskets, less than 15-point change in Shore A duction of AEM to the market, the eth- A smaller, but increasingly more im- O-rings and other seals in the air and oil Hardness. ylene-methacrylate ratios have been opti- portant area, is flame retardant applica- circuit of the car covering a temperature Standard Vamac compounds will mized to meet market needs and form the tions. AEM polymers are halogen-free range from -40° to +160°C. withstand long-term (1,000 hours) heat basis of the current portfolio offerings. and can be compounded with large Standard Vamac compounds use car- aging at 150-160°C and short term (168 Besides the monomer ratio, different vis- quantities of halogen-free flame retar- bon black or inorganic fillers for rein- hours) up to ~190°C. Long-term heat cosity grades have been added to improve dant fillers to provide compounds with forcement, which accelerate oxidative aging at 175°C or short term at 200°C, polymer handling and properties, and very low smoke emission and toxicity, degradation. To increase the heat resis- however, exceed the upper temperature also to allow for more flexible compound- which is becoming more and more im- tance, the VMX5000 pre-compounds se- limit, and VMX5000 pre-compounds ing strategies for customers. portant for wire and cable use in the ries utilize a novel filler system that of- present an alternative higher-heat re- The majority of Vamac-brand applica- transportation and/or building sector. fers 10° to 15°C improved heat resistance sistant material before moving to costli- tions are in the automotive sector, where The latest new polymer additions to over conventional carbon black-filled er FKM options. heat and oil resistance are critical. For the Vamac portfolio and compounding AEM or HT-ACM, while maintaining Fig. 2 shows the retained elongation seals and gaskets, fast curing compounds studies related to these three main ap- very good physical properties and fluid at break after different heat aging con- with excellent compression set resistance plication areas are discussed in the fol- resistance. ditions. The VMX5015 compound shows combined with heat and fluid resistance lowing passages. Vamac VMX5000 series pre-compounds improved behavior after long-term aging can be seen as an interesting cost-effec- at 175°C and also short term at 200°C Table 1: DuPont Vamac grades by application areas. tive alternative to FKM materials in the compared to Standard Ultra AEM. A temperature range between -35° and peroxide-cured FKM compound is +175°C, especially when good resistance shown for comparison. to aggressive oil-acid mixtures and good Besides retention of properties after low temperature performance is re- heat or fluid aging, industry standard quired. Fig. 1 shows temperature rating See Polymers, page 20

Fig. 2: Heat aging at different temperatures: Ultra IP vs. VMX5015 and FKM (70ShA).

Fig. 1: Temperature rating of VMX5000 pre-compounds vs. Vamac Ultra and HT-ACM. Fig. 3: CSR in air at 165°C: Vamac Ultra IP and VMX5015 vs. HT-ACM.

P018_P021_RPN_20201130.indd 18 11/25/20 3:48 PM See Polymers, page 21 www.rubbernews.com www.rubbernews.com Rubber & Plastics News • November 30, 2020 19 Technical

nician. In 2003 he joined DuPont at the He also has four patents. DuPont, leading research on Vamac technical center in Geneva as a technical Mark Stewart received his bachelor’s and Hytrel at the Experimental Station New developments in properties representative. He currently works for degree and co-operative education certifi- in Wilmington. He received bachelor’s DuPont in technical service and develop- cate in chemical engineering from Purdue and master’s degrees in chemical engi- ment, and he oversees the testing and University in 1992. He joined DuPont op- neering from Carnegie-Mellon Univer- process laboratory for Vamac. erations at the Sabine River Works eth- sity and the University of Delaware in for ethylene acrylate polymers Ed McBride received a bachelor’s de- ylene unit in Orange, Texas, and in 1995 1980 and 1982, respectively. gree in chemical engineering from the was assigned to ethylene copolymers op- Elias Wang received his bachelor’s in The authors University of Virginia in 1979. He has erations support, including Vamac. chemical engineering and technology worked for DuPont since then in a vari- In 1997, Stewart transferred to the from Shanghai Jiao Tong University in ety of assignments, including manufac- DuPont Experimental Station in Wilm- China in 2003. He joined DuPont China turing, R&D and technical services. He ington to lead the ethylene copolymers R&D Center in 2005 to set up the packag- currently is located in Wilmington and R&D pilot plant operations. After complet- ing and industrial polymer laboratory. He focuses on the Vamac product line. ing certification for Six Sigma Black Belt moved to work on Vamac in a technical McBride has authored or co-authored in 2004, he assumed his R&D role on Va- service and development role from 2008, more than 30 technical papers and has mac elastomers as a principal investigator. and the following year assumed a similar written several chapters in textbooks. Steve Oriani is a technical fellow at role for Viton elastomers.

Kammerer Bouvier

based on three industry-accepted crite- ria: less than 50 percent loss in tensile strength and elongation at break, and less than 15-point change in Shore A Hardness. McBride Stewart Standard Vamac compounds will withstand long-term (1,000 hours) heat aging at 150-160°C and short term (168 hours) up to ~190°C. Long-term heat aging at 175°C or short term at 200°C, however, exceed the upper temperature Who needs data? Your business! limit, and VMX5000 pre-compounds present an alternative higher-heat resistant material before moving to costli- er FKM options. Fig. 2 shows the retained elongation Check out the RUBBER & PLASTICS News’ Data Store for scores of at break after different heat aging con- Oriani Wang ditions. The VMX5015 compound shows improved behavior after long-term aging Patricia Panne rankings AND LISTS THAT CAN HELP YOU RUN YOUR BUSINESS TODAY at 175°C and also short term at 200°C received her doc- compared to Standard Ultra AEM. A torate in chem- peroxide-cured FKM compound is istry from the HERE ARE THE RECENT ADDITIONS TO THE STORE: shown for comparison. University of Co- Besides retention of properties after logne, Germany, heat or fluid aging, industry standard in 2004. After a Global Tire Report: 2020 Top 75 Global Tire See Polymers, page 20 postdoctoral fel- Company rankings. Includes the world’s tire lowship in the Fig. 2: Heat aging at different temperatures: Ultra IP vs. VMX5015 and FKM (70ShA). U.S., she joined production facilities by region. DuPont Central Panne Research & Devel- opment in Wilmington, Del., working North American Rubber Rankings: on a variety of programs focusing on high temperature performance elas- Annual Spreadsheet of the Top 50 North American tomers. rubber product manufacturers She moved back to Germany in 2014 and worked as R&D Head of Global non-tire Top 50 Automotive at Klueber Lubrication before re-joining DuPont in 2016 in a technical service and development North American Top-50 role for the firm’s Vamac-brand elastomers. Rubber company earnings, operating ratios, Klaus Kammerer received his de- sales/employees gree in chemistry from the Universi- ty of Ulm, Germany, in 1992. After Use promo code: crainRPN10 for 10% off. five years in the rubber industry at DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW TOP Limited time only. INDUSTRIAL DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW Kettlitz-Chemie, he joined DuPont DOWNLOAD DOWNLOADNOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD OUR NOW DOWNLOAD NOW DOWNLOAD NOW Fig. 3: CSR in air at 165°C: Vamac Ultra IP and VMX5015 vs. HT-ACM. DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW TOP DOWNLOAD NOWINDUSTRIAL DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW in 1998 at its European Technical DOWNLOAD RANKINGSNOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOADAND NOW DOWNLOAD LISTS NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW See key on Page 15 Centre in Geneva, Switzerland, as DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW Custom Mixing: Excel formatted spreadsheet lists DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW technical representative for Vamac DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW DOWNLOAD NOW ethylene acrylic elastomers. the North America custom mixing suppliers. In 2003, he moved back to South- ern Germany, and since then has worked for DuPont in technical service and application development for high performance elasto- These and so much more are online today. Don’twait. Visit: mers such as Viton and Vamac. Serge Bouvier received his Ad- vanced Federal Diploma of Labora- rubbernews.com/data-lists tory technician in physics from the Physics University of Geneva in 1995. He joined DuPont Dow Elas- Visit other Global Polymer Group websites for additional data: plasticsnews.com/data-lists tomers S.A. in Geneva, Switzer- land, in 1997 as a laboratory tech- and tirebusiness.com/data-lists. Need customized data? Contact Lori DiFrancesco at [email protected] or Hollee Keller at [email protected].

P018_P021_RPN_20201130.indd 19 11/25/20 3:48 PM See Polymers, page 21 20 Rubber & Plastics News • November 30, 2020 www.rubbernews.com www.rubbernews.com Technical Technical

polar elastomers. However, the additive need the best compression set, slow-cur- tion of as much fillers as can be used for packages of these fluids are more aging polymers with best scorch resistance 70 Shore A, and therefore total com- Polymers gressive and lead to significantly more have been introduced to the market. The pound cost of the Ultra HT or HT-OR Polymers crosslinking during oil aging tests. grades widely used are Vamac GXF (17.5 based compounds is higher than for Va- Continued from page 18 Table 2 shows the hardness increase Mooney, introduced 2003), Vamac Ultra mac GXF-based compounds. Continued from page 20 tests to judge the sealing performance of and loss of elongation after aging in low HT (29 Mooney, 2009) and its high MA As customers do not want to use poly- when GXF is used as a base polymer for a material include compression set (CS) viscosity oil Lukoil Genesis MC 0W-20 of version Ultra HT-OR (31 Mooney, 2011) mer blends in dynamic applications, Va- hose cover layers to get good compound and also compressive stress relaxation standard AEM, VMX5000, ACM and for lower volume swell in oils. mac Ultra XF is now an alternative grade flow and good interlayer adhesion. (CSR). CSR testing in particular gives HT-ACM compounds. Carbon black- Recently, a new grade with intermedi- allowing for extrusion of 70-75 Shore A an idea about long-term sealing perfor- filled AEM and especially ACM show a ate viscosity (23 Mooney, formerly compounds, which still have superior Flame retardant applications mance of a material exposed to air or strong hardness increase and loss of VMX3041) was developed to provide green strength and physical properties Vamac DP and Vamac Ultra DX fluid. AEM is known for its excellent elongation after the fluid aging. customers with a broader choice of AEM compared to Vamac GXF. Table 3 shows (VMX2122) are peroxide-curable di- performance in CSR testing vs. ACM or VMX5000, however, offers a signifi- grades for hose applications. Typical some standard recipes with Hardness polymers and the first choice for com- HT-ACM. Fig. 3 shows the improvement cant improvement. The additional for- TCH made from Vamac GXF have been between 60 and 75 Shore A. Tensile pounds where fire safety and low com- that VMX5000 based compounds offer mation of crosslinks during fluid aging produced in 70-75 Shore A Hardness strengths, elongation at break and compound toxicity is critical. Both grades in air at 165°C. also is seen as a negative effect during compounds. The higher viscosity grades pression set improves as viscosity and can be compounded with high amounts At continuous temperatures of 175°C, long-term compression set. Ultra HT and HT-OR provide better molecular weight increases. of typical non-halogenated flame retar- standard AEM is typically not used In summary, the VMX5000 series of- physical properties and better compres- The Mooney viscosity of a Vamac Ul- dant fillers, like aluminum or magne-

anymore. As Fig. 4 shows, the seal force fers an extended temperature range sion set resistance, and thus may be tra HT vs. a Vamac Ultra XF compound sium hydroxide (ATH, Mg(OH)2) with- of standard AEM compounds is below 20 from -35° to 175°C with the option to used at even higher temperatures. is about 6-7 MU higher at equal filler out negatively impacting compound percent. VMX5000 compounds still have possibly replace FKM in some areas, However, as these higher tempera- content. This allows better extrusion of 20 percent seal force left after six weeks improved oil resistance in new engine tures do not always allow the use of sig- an Ultra XF-based compound at given Fig. 4: CSR in air at 175°C: Vamac standard and VMX5000 vs. FKM. and offer an alternative solution to FKM oils and automotive fluids, plus excel- nificant amounts of plasticizer, the vis- hardness, or allows the use of roughly 7 in that temperature range. lent sealing performance for black and cosity of compounds based on Ultra HT to 8 phr more FEF N-550 in the Ultra In addition to the increased heat re- colored compounds. and HT-OR sometimes leads to very XF compound to reach the same Mooney sistance, VMX5000 based compounds high pressures during the extrusion of viscosity as Ultra HT (Fig. 5). show very good resistance to engine and Hose applications with 70 Shore A compounds. Therefore, Ultra Thus, Ultra XF can provide cost savings transmission oils. The new low viscosity optimized extrusion process HT and HT-OR often are compounded at by higher filler loadings. Vamac GXF oils are more and more based on aliphat- For dynamic hose applications such as lower Hardness levels between 60 and provides even lower Mooney and can help ic base oils, which cause lower swell in turbocharger hoses (TCH), which do not 65 Shore A. This does not allow the addi- See Polymers, page 21

Lynn Calcaterra Classified Sales Manager Phone: 313-446-0446

A Crain Publication Email: [email protected] Classifi eds Visit our website at: www.rubbernews.com

CUSTOM MANUFACTURING Don’t Miss Your Chance to Advertise in These 2020 STIMULUS Table 2: Comparison of AEM, VMX5000, ACM and HT-ACM in 0W-20 oil. Upcoming Issues December 14 COME BACK SPECIAL Tire engineering and 2020 Year in Review/ specialty tire manufacturing. Executive of the Year Great new incentive to jump-start ISO-registered custom mixing, calendering Closes: December 2 your company’s message! and gum calendering processes. December 28 Contact Jerry Mikesell at 574.784.3409 or email: [email protected] THE BOOK www.hoosiertirecustommfg.com The one-stop resource Don’t Miss Out — Limited Time Only! for the latest and most June 15 – December 14, 2020 CUSTOM GRINDING SERVICES EQUIPMENT FOR SALE sought-after news in the industry For more information contact: CUSTOM GRINDING SERVICE Plastics & Rubbers Used Rubber & Plastics Equipment Lynn Calcaterra | Classiﬁed Sales Manager Toll: Pulverizing Granulating We Buy & Sell All Types Cryogenic Grinding & Pulverizing www.rubberandplasticsequipment.com 313.446.0446 | [email protected] Sifting Blending Repackaging [email protected] Lab to production size equipment As-is to re-furbished. Call 330-631-7823 Timely. Technical. Trusted. 908-479-4400 I-78 Bloomsbury NJ www.allgrind.com [email protected]

Table 3: Formulation and physical properties of GXF, Ultra XF and Ultra HT compounds.

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P018_P021_RPN_20201130.indd 20 11/25/20 3:49 PM www.rubbernews.com www.rubbernews.com Rubber & Plastics News • November 30, 2020 21 Technical tion of as much fillers as can be used for viscosity, such is often seen with Vamac Besides excellent heat resistance, Va- pounding options to obtain materials 70 Shore A, and therefore total com- terpolymers. mac HFFR compounds show low swell in with excellent heat and chemical resis- pound cost of the Ultra HT or HT-OR Polymers Vamac’s linear polymer structure al- oils, e.g. IRM 903, while maintaining tance, low temperature flexibility and based compounds is higher than for Va- lows rapid extrusion in very thin cable superior low temperature flexibility. low fire hazard properties. mac GXF-based compounds. Continued from page 20 diameters with very smooth surfaces. For example, Vamac compounds will Table 5 gives an overview about the As customers do not want to use poly- when GXF is used as a base polymer for This allows the extrusion of very flexible have a ca. 10°C lower Tg at a comparable obtainable flammability properties of a mer blends in dynamic applications, Va- hose cover layers to get good compound cables at low weight. oil swell to EVM and a ~20-30 percent Vamac Ultra DX compound and a 70/30 mac Ultra XF is now an alternative grade flow and good interlayer adhesion. Vamac-based polymers are not inher- better oil resistance at the same Tg as blend of Ultra DX/Hytrel 4056 in com- allowing for extrusion of 70-75 Shore A ently resistant to burning and have a EVM (Fig. 6). parison to EVM 700. compounds, which still have superior Flame retardant applications limited oxygen index (LOI) of ~21 per- Frequently, Vamac HFFR compounds In summary, Vamac dipolymers offer a green strength and physical properties Vamac DP and Vamac Ultra DX cent. However, in compounds with flame for wire and cable applications are variety of compounding options to obtain compared to Vamac GXF. Table 3 shows (VMX2122) are peroxide-curable di- retardant fillers, like ATH (e.g. 150 phr) blended with thermoplastic polymers, halogen-free flame retardant compounds some standard recipes with Hardness polymers and the first choice for com- the LOI is increased to >35 percent and partly to reduce cost but also to improve with very low smoke and toxicity emission between 60 and 75 Shore A. Tensile pounds where fire safety and low com- the UL-94 V-0 protocol is easily passed. processing and physical properties. while providing good heat and oil resis- strengths, elongation at break and compound toxicity is critical. Both grades Physical properties of a standard halo- Suitable thermoplastic resins include tance and low temperature flexibility. pression set improves as viscosity and can be compounded with high amounts gen-free flame retardant (HFFR) start- Elvax-brand (ethylene-vinyl acetate co- molecular weight increases. of typical non-halogenated flame retar- ing point formulation (150 phr ATH, 5 polymer with 40 wt percent VA) and This paper was first presented at the The Mooney viscosity of a Vamac Ul- dant fillers, like aluminum or magne- phr peroxide, 2 phr co-agent) is shown in Hytrel-brand (thermoplastic polyester 2019 International Rubber Conference in tra HT vs. a Vamac Ultra XF compound sium hydroxide (ATH, Mg(OH)2) with- Table 4 and show the difference of Va- elastomer). These offer further com- London. is about 6-7 MU higher at equal filler out negatively impacting compound mac DP vs. Ultra DX. content. This allows better extrusion of Fig. 5: Mooney viscosity vs. carbon black loading. an Ultra XF-based compound at given Fig. 4: CSR in air at 175°C: Vamac standard and VMX5000 vs. FKM. hardness, or allows the use of roughly 7 to 8 phr more FEF N-550 in the Ultra XF compound to reach the same Mooney viscosity as Ultra HT (Fig. 5). Thus, Ultra XF can provide cost savings by higher filler loadings. Vamac GXF provides even lower Mooney and can help See Polymers, page 21

Lynn Calcaterra Classified Sales Manager Phone: 313-446-0446

A Crain Publication Email: [email protected] Visit our website at: www.rubbernews.com Classifi eds Table 4: Comparison of Vamac DP and Ultra DX in an HFFR formulation.

CUSTOM MANUFACTURING Don’t Miss Your Chance to Advertise in These 2020 STIMULUS Table 2: Comparison of AEM, VMX5000, ACM and HT-ACM in 0W-20 oil. Upcoming Issues December 14 COME BACK SPECIAL Tire engineering and 2020 Year in Review/ specialty tire manufacturing. Executive of the Year Great new incentive to jump-start ISO-registered custom mixing, calendering Closes: December 2 your company’s message! Fig. 6: Comparison oil swell and Tg of AEM vs. EVM. and gum calendering processes. December 28 Contact Jerry Mikesell at 574.784.3409 or email: [email protected] THE BOOK www.hoosiertirecustommfg.com The one-stop resource Don’t Miss Out — Limited Time Only! for the latest and most June 15 – December 14, 2020 CUSTOM GRINDING SERVICES EQUIPMENT FOR SALE sought-after news in the industry For more information contact: CUSTOM GRINDING SERVICE Plastics & Rubbers Used Rubber & Plastics Equipment Lynn Calcaterra | Classiﬁed Sales Manager Toll: Pulverizing Granulating We Buy & Sell All Types Cryogenic Grinding & Pulverizing www.rubberandplasticsequipment.com 313.446.0446 | [email protected] Sifting Blending Repackaging [email protected] Lab to production size equipment As-is to re-furbished. Call 330-631-7823 Timely. Technical. Trusted. 908-479-4400 I-78 Bloomsbury NJ www.allgrind.com [email protected]

Table 3: Formulation and physical properties of GXF, Ultra XF and Ultra HT compounds.

Table 5: Flammability data of AEM, AEM/Hytrel blends vs. EVM700.

P018_P021_RPN_20201130.indd 21 11/25/20 3:50 PM