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The localization of the rubber vulcanization reaction close to the silica filler surface was investigated in isoprene rubber composites (IR NCs): the main goal was to highlight the role of curing agents’ dispersion and filler surface features on the spatial propagation of the rubber cross-links and the resulting mechanical behavior of the material. The study was realized by tailoring the morphology of the curing activator, i.e. by vulcanizing IR NCs with Zn@SiO2 double function filler, composed of Zn(II) single sites anchored on SiO2 filler, in comparison to silica filled IR NCs vulcanized with microcrystalline ZnO. The microscopic cross-links distribution was measured by Transmission Electron Microscopy for network visualization (NVTEM) and Time Domain Nuclear Magnetic Resonance (TD-NMR). Besides the NCs mechanical behavior was characterized both at small strain and at fracture. In the presence of Zn@SiO2, higher cross-link density in proximity to SiO2 particles was evidenced, which gradually spreads from the filler surface to the bulk, induced by localization of the Zn(II) centers. IR NCs with Zn@SiO2 resulted stiffer (+45%) and with a lower fracture toughness (less than one third), compared to m-ZnO based NCs, which shows a quite homogeneous structure of the rubber cross-links network. The results highlighted the correlation between the composites structural features and their macroscopic behavior, paving the way to modulating the mechanical properties of elastomeric materials by tuning the nature of the curing agents.

The interaction between activators (ZnO) and co-activators (stearic acid, SA) represents a key step in the vulcanization process, to generate Zn(II) intermediate complexes that enhance the reaction kinetic and promote the shortening of sulfur bridges, leading to highly cross-linked materials. To understand the influence of the structural, morphological and surface properties of ZnO in the reactivity with SA, in this work, pure ZnO nanoparticles (NPs) and ZnO NPs anchored on SiO2 (ZnO/SiO2) were prepared through soft chemistry techniques. Tailoring of morphology and surface features was accomplished through a fine control of the synthetic parameters, as demonstrated by the careful characterization of the activators. Then, the interaction of pure ZnO and ZnO/SiO2 activators with SA in the absence of rubber was investigated by using Differential Scanning Calorimetry (DSC). The occurrence of Zn(II)-SA complexes with different thermal stability and structural properties was assessed by a comprehensive thermogravimetric and spectroscopic survey. The generation and the chemical structure of these specific vulcanization intermediates was related to the peculiar characteristics of the ZnO/SiO2 systems and, in turn, to their ability in imparting faster kinetics and higher curing efficiency to isoprene rubber nanocomposites, compared to bare ZnO. These results, besides proposing a valid benchmark for achieving further insights on the interaction of stearic acid with activators, pave the way to provide specific protocols for a better design and implementation of ZnO-based materials able to effectively enhance the rubber vulcanization process, with significant economic and environmental advantages.

The crosslink density and distribution inside the polymer matrix affect the mechanical properties of rubber nanocomposites (NCs). Since the catalytic activity of zinc has a central role in the formation of crosslinks, this study focuses on the effect that the structure of the catalytic sites and their localization inside the polymer matrix have on the mechanical behavior of rubber materials. To do this, a new highly efficient activator, Zn@SiO2 based on zinc single sites anchored onto the silica surface, is used as double function filler, acting as both activator and reinforcing filler. The mechanical properties of rubber NCs prepared with Zn@SiO2 are compared to NCs conventionally cured with ZnO particles. The results suggest that localizing the catalytic sites at different distance from the filler particles dispersed in the rubber matrix is a promising tool to control the crosslinking density and distribution, which means tuning the mechanical properties of rubber NCs.

The efficiency of sulfur vulcanization reaction in rubber industry is generally improved thanks to the combined use of accelerators (as sulphenamides), activators (inorganic oxides), and co-activators (fatty acids). The interaction among these species is responsible for the formation of intermediate metal complexes, which are able to increase the reactivity of sulfur towards the polymer and to promote the chemical cross-links between the rubber chains. The high number of species and reactions that are involved contemporarily in the process hinders the complete understanding of its mechanism despite the long history of vulcanization. In this process, ZnO is considered to be the most efficient and major employed activator and zinc-based complexes that formed during the first steps of the reaction are recognized to play a main role in determining both the kinetic and the nature of the cross-linked products. However, the low affinity of ZnO towards the rubber entails its high consumption (3–5 parts per hundred, phr) to achieve a good distribution in the matrix, leading to a possible zinc leaching in the environment during the life cycle of rubber products (i.e., tires). Thanks to the recent recognition of ZnO ecotoxicity, especially towards the aquatic environment, these aspects gain a critical importance in view of the urgent need to reduce or possibly substitute the ZnO employed in rubber vulcanization. In this review, the reactivity of ZnO as curing activator and its role in the vulcanization mechanism are highlighted and deeply discussed. A complete overview of the recent strategies that have been proposed in the literature to improve the vulcanization efficiency by reducing the amount of zinc that is used in the process is also reported.