Polybutadiene - The Versatile Synthetic Rubber

Polybutadiene
Polybutadiene


 Introduction

Polybutadiene, commonly known as 'butadiene rubber' or BR, is a synthetic rubber produced through the polymerization of the monomer 1,3-butadiene. It is a polymer with excellent mechanical properties and finds uses across diverse industries. In this article, we will explore the production process, properties, applications and future prospects of polybutadiene.

Production Process
Polybutadiene is produced through a process known as 'solution polymerization'. In this process, 1,3-butadiene monomer is dissolved in an organic solvent like hexane or heptane in the presence of an initiator and then polymerized at high temperatures between 60-90°C. Common initiators used are organic peroxides or azo compounds which help in kicking off the radical polymerization reaction. The reaction generates high molecular weight polybutadiene polymer chains within a short span of 3-4 hours. After polymerization, the solvent is removed through evaporation leaving behind a pale yellow to off-white colored synthetic rubber. The properties and structure of polybutadiene can be tailored by controlling reaction parameters like temperature, choice of solvent, type of initiator etc.

Properties
Polybutadiene has excellent mechanical properties like flexibility, tensile strength, abrasion and tear resistance which make it suitable for various applications. Its properties can be broadly categorized as:

- Elasticity: High elongation at break of over 500% enables high flex resistance and comfort.

- Toughness: Above average impact strength and tear resistance enables use in tires and other products requiring durability.

- Temperature Resistance: It has a service temperature range of -50°C to +80°C making it ideal for applications across climatic conditions.

- Aging Resistance: Slow rate of oxidative aging helps preserve its properties over long term use.

- Chemistry: The double bonds in its structure allows for vulcanization and functionalization reactions to tailor its properties.

The microstructure and hence properties of polybutadiene depend on the cis-trans ratio of the double bonds along the polymer chain. Industrial grades typically have a cis content between 80-98%.

Applications
Owing to its versatile mechanical properties, polybutadiene finds diverse applications ranging from tires, footwear to adhesives and construction. Some key applications are:

Tires - As tire tread and sidewall material, Polybutadiene  provides cushioning, wear resistance and flex durability important for tires. Around 65% of BR produced worldwide goes into tire manufacturing.

Footwear - Used in shoe soles and heels, it provides cushioning and flexibility vital for comfort in footwear.

Industrial Rubber Products - Hoses, belts, gaskets, seals utilize its ability to withstand vibration and flex fatigue over extended use.

Adhesives - Its adhering properties make it useful in contact adhesives, sealants and emulsion adhesives.

Sports Goods - In articles like bowling balls, sports mats etc where resiliency and toughness are key.

Modification and Future
Traditional polybutadiene can be further modified to introduce improved properties. Some notable modified variants are:

- High Cis Polybutadiene - Increased cis content above 95% provides enhanced strength and hardness for specialized tire compounds.

- Butyl Rubber - Copolymerization with 15-45% isobutylene introduces improved air retention for innerliners in tubeless tires.

- Acrylonitrile Butadiene Rubber (NBR) - Copolymer of acrylonitrile and butadiene with oil and solvent resistance and strong adhesion.

With the increased focus on sustainability, new generation polybutadienes synthesized from plant based bio-butadiene are also being researched which can reduce fossil resource dependency. Continuous product innovation focusing on reinforcement of properties, development of specialty grades and bio-based variants will pave the way for polybutadiene rubber in the future.

Polybutadiene has established itself as a dependable synthetic rubber owing to its ability to deliver performance at economic costs. Versatile mechanical properties along with easy processability have enabled it to effectively replace natural rubber in many applications. Continuous efforts to further enhance its strengths and develop new specialty variants will ensure it remains relevant in the rubber industry going forward.

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