Recycled rubber wastes-based polymer composites with flame retardancy and electrical conductivity: Rational design, modeling and optimization

Abstract

Polymer recycling techniques experience a maturity period of design and application. Rubbers comprise a high proportion of polymer wastes, highly flammable and impossible to re-melt. Polymer composites based on ground tire rubber (GTR) and ethylene-vinyl acetate copolymer (EVA) containing carbon black (CB) (1–50 phr), with variable EVA/GTR weight composition (10/90, 25/75, 50/50, 75/25 and 90/10), and processing temperature (Low: 100 °C and High: 200 °C) were designed applying Design of Experiments (DOE) approach of Optimal Design. The properties and performance features were experimentally evaluated. The tensile strength (TS) and elongation at break (EB) were optimized using Desirability Function (DF) approach. A wide fluidity window (Labeled POOR, GOOD, and EXCELLENT) and mechanical properties were observed. Overall, higher values of EB were assigned to samples processed at 200 °C. Cubic regression modeling and DF optimization of TS and EB indicated unlikely that one expect a TS ≥ 3 MPa, while EB values more than 500% were likely regardless of CB content for EVA-rich composites. The electrical properties of CB/EVA/GTR samples were examined by impedance spectroscopy technique. An interesting relationship was observed between the DC conductivity and the EVA/GTR ratio and processing temperature. GTR-rich samples showed much higher conductivity than EVA-dominated samples, attributed to the presence of CB in the rubber waste, which, together with the added CB, was able to create conduction paths for the transported electrons. Higher processing temperature of 200 °C improved dispersion of the added CB, i.e. a more even distribution of the conductive phase in the matrix. The uniform and evenly dispersed domains of particles were detected by SEM images for highly CB loaded composites. Surprisingly, 50/50 EVA/GTR composites were resilient against flame, while thermally stable ones in TGA measurements were highly CB loaded ones.