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The incorporation of nanoscale particles into elastomers enable a boost in performance and/or a distinct reduction of conventional filler loadings due to their high surface to volume ratio. 2D layered nanoparticles like graphene and graphene-related materials provide a great potential as effective fillers in rubber, especially by enhancing mechanical and barrier properties. The type and properties of the nanoparticles, their interface and the elastomeric matrix materials influence the technical behavior, and therefore the potential application fields of such rubber nanocomposites. Especially crucial for the efficiency of the nanofiller, however, is its best possible incorporation into the elastomer. The dispersing of nanoparticles without agglomerates usually constitutes a challenge when using conventional two-roll milling or internal mixing. Academic approaches for highly dispersed nanocomposites solve this problem but are often energy and time consuming with no feasible scale up possibility. Therefore, an ultrasonic assisted NR latex premixing process was established to produce highly filled masterbatches, enabling the main processing with conventional rubber processing techniques.
Two carbon-based nanoparticles with similar specific surface areas were investigated and incorporated in natural rubber as nanocomposites: A commercially available multilayer graphene (MLG) and a nanoscale carbon black (nCB). The mentioned premixed masterbatches were further processed to nanocomposites by the addition of matrix NR, two-roll milling, and hot pressing (vulcanization). By this procedure an increase in Young’s modulus of 157% (MLG) and 71% (nCB) could be obtained at a concentration level of 3 phr. As anisotropic material behavior was observable for the nanocomposites containing MLG, different measurement methods were investigated to quantify the orientation of the nanoparticles in the nanocomposites: Sorption measurements (swelling in 2 dimensions), hardness and dynamical mechanical analysis (in-plane vs. cross-plane), X-Ray diffraction and transmission and scanning electron microscopy.
The addition of nanoparticles as reinforcing fillers in elastomers yields nanocomposites with unique property profiles, which opens the door for various new application fields. Major factors influencing the performance of nanocomposites are studied by varying the type and shape of nanoparticles and their dispersion in the natural rubber matrix. The industrial applicability of these nanocomposites is put into focus using two types of graphene and a nanoscale carbon black, all commercially available, and scalable processing techniques in the form of a highly filled masterbatch production via latex premixing by simple stirring or ultrasonically assisted dispersing with surfactant followed by conventional two-roll milling and hot pressing. Different processing and measurement methods reveal the potential for possible improvements: rheology, curing behavior, static and dynamic mechanical properties, swelling, and fire behavior. The aspect ratio of the nanoparticles and their interaction with the surrounding matrix prove to be crucial for the development of superior nanocomposites. An enhanced dispersing method enables the utilization of the improvement potential at low filler loadings (3 parts per hundred of rubber [phr]) and yields multifunctional rubber nanocomposites: two-dimensional layered particles (graphene) result in anisotropic material behavior with strong reinforcement in the in-plane direction (157% increase in the Young's modulus). The peak heat release rate in the cone calorimeter is reduced by 55% by incorporating 3 phr of few-layer graphene via an optimized dispersing process.