Compounding and extrusion are critical steps in the production of rubber compounds of a reliable quality within a given timeframe and hence at a reasonable cost. The materials used - including the rubber types -are varied in order to obtain improvements in product performance. One of the most important of the synthetic rubbers is neodymium polybutadiene (NdBR) which, because of its exceptional microstructure and macrostructure, offers outstanding properties. Through the use of high-cis NdBR, marked improvements have been obtained in end products in terms of dynamic performance and good fatigue and wear characteristics. At the same time, however, the processing behaviour of this type of rubber requires adjustments to be made at the compounding and extrusion stage. This can lead to problems in the handling of the milled sheet and profiles, resulting for example in severe surface roughness or die swell. In extreme cases the benefits of NdBR can be masked altogether if no adjustments are made to the processing stages. This paper presents countermeasures to improve the processability of NdBR by adapting the compounding and extrusion conditions to its specific requirements. The ratio of viscosity and elasticity is specific to each type of rubber and therefore requires individual adjustment of the processing conditions. We show that under appropriately adjusted conditions, even using NdBR grades with the highest molecular weights (e.g. Buna CB22), short compounding times and smooth milled sheets and extrusion profiles with a glossy surface can be obtained. Under these conditions neodymium polybutadiene rubbers provide a basis for an ideal combination of excellent material properties and improved processing behaviour. The positive characteristics of NdBR are retained when it is used in blended rubbers such as an SSBR/BR blend. The rules regarding the optimisation of process conditions for pure NdBR systems apply here too.
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