One of the current problems faced by mankind is the problem of safe disposal of waste rubber. Statistics show that the number of waste tires is continuously increasing at a very rapid rate. Since rubber materials do not decompose easily (due to their crosslinked structure), they end up being a serious ???environmental problem???. An intuitive solution to prevent the accumulation of the scrap tires is to continuously reuse them. A new patented reclamation method was discovered in our laboratory, which makes use of a twin screw extruder (TSE) in order to produce reclaimed rubber (referred as devulcanized rubber (DR) from here on) of very high quality. Also, this method has proven to be more economical than other commercial reclaiming methods. Products made solely from a reclaimed material face challenges from those made by virgin materials because of relatively poor properties. However, the striking advantage of using reclaimed rubbers is the cost reduction. Hence, it is important to work on establishing methods by which these reclaimed rubbers could be efficiently used and incorporated into present day products. The deterioration of properties could be minimized by blending them with varying amounts of other materials. A possibility in this direction is manufacturing of thermoplastic vulcanizates (TPVs) using reclaimed rubber and general purpose thermoplastics. In accordance with this idea, the focus of this research is to prepare DR and polypropylene (PP) based TPVs. DR is unique as the rubber itself consists of two phases- one phase consisting of uncrosslinked (including devulcanized rubber molecules), and the other phase consisting of crosslinked (un-devulcanized) rubber. These un-devulcanized crumbs act as stress concentrators because they do not break-up easily, and lead to poor physical properties. Hence, this project tries to find out ways to increase the interfacial adhesion between the rubber and PP by using reactive and non-reactive techniques. Preliminary experiments were carried out in a batch mixer to compare DR and rubber crumb (CR). DR based TPVs showed better properties than CR based TPVs, however, the properties were not useful for commercial applications. Sulphur based dynamic vulcanization was studied in a batch mixer and found to be not effective in improving the properties of DR based blends. On the other hand, DCP/ sulphur based curing system was found to show significant improvement in properties. Therefore, DCP/sulphur based curing package was studied in detail on the blends consisting of DR and PP. The optimum ratio of DCP/sulphur was found to vary depending on the ratio of DR/PP. A hypothesis regarding the mechanism of DCP/sulphur curing has been proposed, which seem to correlate well with the experimental results observed. Additionally, it was determined that DR prepared from tire rubber (DRT) performed better than DR prepared from waste EPDM (DRE) for the curing system used. Accordingly, experiments on a TSE were carried out using DRT and a combination of compatibilizing resins and curatives. This combination showed a drastic improvement in blends properties and once again the optimum ratio of compatibilizing resins seemed to depend on the ratio of DRT/PP. As a result of the work, successful strategies based on reactive compatibilization techniques were developed in order to prepare useful TPVs having up to 70% DR. A series of compatibilization techniques has been evaluated using design of experiments and various characterization techniques such as mechanical tests, scanning electron microscopy, thermal analysis and crosslink density measurements. This led to the development of a formulation, which could improve the blend properties significantly. A tensile strength of around 10 MPa and an elongation-at-break of 150-180 % could be achieved for devulcanized rubber (70%) based TPVs, which has broadened the scope for its commercial applications. In addition to that, the process was established on a TSE that has enabled a continuous and steady production of these TPVs with reasonable throughputs.

La préparation du caoutchouc naturel hydrogéné (HNR) par réaction avec l'hydrazine et le peroxyde d'hydrogène et le latex de caoutchouc naturel a été intéressée. L’influence de conditions de réaction, types et volume de solvants, volume du  réactionnel, la quantité d’hydrazine et de peroxyde d’hydrogène sur le degré d’hydrogénation du caoutchouc naturel a été étudiée. Le structure et  détermination du degré d’hydrogénation des caoutchoucs naturel hydrogénés a été analysée par  résonance magnétique nucléaire (RMN), transformée de fourier infrarouge (FTIR) et spectroscopie Raman. Un degré d'hydrogénation de 18 % a été obtenu à 1.0 - 2.0 du la molaire de d’hydrazine et de peroxyde d’hydrogène, température optimale de 50°C et le temps de réaction de 24h. Afin d'améliorer le degré d'hydrogénation, des solvants tels que le toluène et le hexane et l'effet de le volume du réactionnel ont été étudiée, ce qui a permis d'obtenir des degrés d’hydrogénation  élevés (proches de 65% avec le toluène). D’autre part, des mesures de tailles de particules de latex ont montré que l’hydrogénation du caoutchouc naturel n’avait pas d’effet sur latex de caoutchouc naturel. Un résultat également intéressant concerne le détermination du taux de gel. Ce gel augmente avec le degré d’hydrogénation, prouvant que des réactions de réticulation ont eu lieu. Néanmoins aucun effet de degré d’hydrogénation sur le température de transition vitreuse n’est détecté. La dureté et viscosités Mooney augmentent, en lien avec l’augmentation du taux de gel. Par ailleurs, la résistance thermique du caoutchouc naturel hydrogéné est considérablement améliorée lorsque le degré d’hydrogénation augmente. Le partie suivante est consacrée à la vulcanisation du caoutchouc. Deux types de réticulation ont été utilisés : au soufre et au peroxyde. Les élastomères HNR réticulés montrent une meilleure résistance à l’ozone et l’UV que le NR réticulé. De plus, cette résistance à l’ozone et l’UV est plus élevée pour le réticulation au soufre, comparée à le réticulation au peroxyde. Une bonne corrélation entre les images de microscopie optique et les résultats des analyses Raman est obtenue. La préparation et l’étude de mélanges HNR/PP obtenus par vulcanisation dynamique en utilisant du peroxyde et du soufre comme agents de réticulation. Un degré d’hydrogénation de 65% a été choisi, et différentes ratio HNR/PP ont été étudiés, et comparés avec des mélanges NR/PP. La morphologie des mélanges a été caractérisée par spectroscopie Raman, ce qui a permis d’obtenir des images cartographie Raman indiquant de façon précise le localisation et la distribution des phases de caoutchouc et de PP.  Une bonne corrélation entre le cartographie Raman et les images de microscopie électronique à balayage (SEM) est obtenue. Ainsi il apparaît que les particules de caoutchouc sont dispersées dans une phase continue de PP, ceci à la fois pour le HNR et le NR. L’étude des propriétés mécaniques a montré que celles-ci étaient gouvernées principalement par le phase continue de PP. / The non-catalytic hydrogenation of natural rubber latex (NRL) was carried out by using diimide generated in situ from the reaction between hydrazine (N2H4) and hydrogen peroxide (H2O2). The effects of mole ratios of [C=C]:[N2H4]:[H2O2], reaction conditions, solvent types, solvent volumes and reaction scale-up on the hydrogenation levels were investigated. Nuclear magnetic resonance (NMR), Fourier transform infrared (FTIR), and Raman spectroscopic techniques were employed to investigate the chemical structure of the hydrogenated natural rubber (HNRs) and to quantify the hydrogenationlevels. It was found that variations in moles of N2H4 and H2O2 in the range of 1.0-2.0 moles resulted in degrees of hydrogenation in the range of 10-18%. Little improvement in hydrogenation levels of HNRs was obtained when NRL particles were swollen in solvents by which toluene yielded better results than hexane. The increase in toluenevolume resulted in the increase in hydrogenation levels up to 42 %. TEM micrographs revealed that swelling mainly occurred at the surface of NRL particles, implying that hydrogenation reaction confined largely at the surface of NRL particles. After removal of toluene, particle size and particle size distribution of partially hydrogenated NRL remained unchanged. To further improve degrees of hydrogenation, the reaction volume was extended and 65% hydrogenation levels were obtained. Therefore, 14%HNR, 33%HNR, and 65%HNR were successfully prepared under suitable reaction conditions. However, crosslinking and cis-trans isomerization were side-reactions occurring during hydrogenation. Gel and trans contents increased with increasing hydrogenation levels, leading to the increase in hardness of HNRs. Mooney viscosities of HNRs increased with increasing degrees of hydrogenation due to the increased gel contents. Mooney torquerelaxation of NR and HNRs were similar. Thermogravimetric analysis revealed that vi HNRs had greater thermal stability than NR and thermal stability increased with increasing degrees of hydrogenation. HNR vulcanizates were much better resistant to ozone and UV than cured NR. Sulfur-vulcanized rubbers had greater ozone resistance than peroxide-cure rubbers due to less amounts of carbon-carbon double bonds present in rubbers. In addition, modulus at low strain and tensile strength of sulfur-cured rubbers were higher than those of peroxide-cured rubbers, but lower elongation due to higher crosslink densities. Also, modulus at low strain and tensile strength increased with increasing hydrogenation levels of HNRs, in contrast to strain at break. Thermoplastic vulcanizates (TPVs) from blends of HNR and Polypropylene (PP) were prepared via dynamic vulcanization using peroxide and sulfur as curing agents. The effects of blend ratios on mechanical properties of TPVs were investigated. Tensile strength increased with increasing PP portions, but breaking strain decreased. Morphology of TPVs was characterized with Raman mapping and scanning electron microscope (SEM). The phase sizes of crosslinked rubber obtained from both techniques were correlated well.

Le travail de thèse présenté dans ce manuscrit a consisté à mettre en avant un nouveau procédé de mélange des polymères développé au LIPHT lors de la mise en oeuvre de mélanges PP/EPDM réticulés dynamiquement et chargés à base de graphène. Ce nouveau mélangeur, appelé RMX®, se distingue de la plupart des mélangeurs existants par la présence d’écoulements élongationnels forts, la possibilité de mouler directement des éprouvettes à l’issue de l’étape de mélange ainsi qu’une étanchéité aux gaz et aux liquides. Après une optimisation des conditions opératoires de ce mélangeur, nous avons pu évaluer quantitativement l’efficacité du mélange dispersif par analyse numérique de tailles de particules d’EPDM dispersées dans une matrice PP. Le RMX® permet d’obtenir une dispersion fine (~ 1 μm) pour des énergies spécifiques et des temps de mélange inférieurs aux procédés existants. Des tailles significativement réduites ont été obtenues pour des mélanges présentant un rapport de viscosité élevé (p > 1). Ces résultats ont été attribués à la combinaison de taux de déformation en cisaillement élevés dans le canal de l’élément de mélange avec des taux de déformation en élongation majoritaires en entrée/sortie de ce dernier. L’impact des écoulements élongationnels sur l’intervalle de (co)-continuité de mélanges PP/EPDM a ensuite été étudié. Un décalage de la percolation de la phase dispersée (EPDM) vers les hautes concentrations ainsi qu’une borne supérieure de cet intervalle plus élevée ont ainsi pu être mis en évidence à l’aide de techniques complémentaires (MEB, extraction sélective de la phase EPDM, analyse rhéologique). Une procédure originale d’élaboration de matériaux TPV dans le RMX® a également été réalisée. La réticulation dynamique au moyen d’une résine phénolique d’un mélange PP/EPDM présentant une morphologie co-continue a été effectuée. Des taux d’insoluble proche de 100% ainsi que les propriétés élastiques des TPV formés ont permis de confirmer l’efficacité de cette étape de réticulation dans le RMX®. Une dernière étude a consisté à disperser une nanocharge graphitique lamellaire et conductrice (xGNPTM) dans une matrice PP. L’analyse par diffraction des rayons X, les seuils de percolation rhéologique et électrique obtenus autour de 7 et 8 wt% respectivement ainsi qu’un facteur de forme Af ~ 15 suggèrent une absence d’exfoliation ainsi qu’une agrégation importante des particules de xGNP. / A new mixing device (RMX®) based on elongational flows has been developed during this work. This device has specific technical features comparing to conventional mixers such as: variable mixing volume, direct molding of samples, air and water tightness. After an optimization of processing conditions, dispersive mixing efficiency was assessed on PP/EPDM blends by numerical analysis. Very fine dispersed morphologies were obtained for lower specific mixing energy and mixing times comparing to internal mixer (Haake Rheomix 600). Significantly reduced droplet sizes have been obtained for high-viscosity ratio blends (p > 1). These results indicate an enhanced droplet break-up mechanism in the RMX® which was attributed to the combination of high shear rates inside the mixing element and important elongational flows in the convergent/divergent zones. Impact of elongational flow mixing on the (co)-continuity interval of PP/EPDM blends was investigated. An important shift (~ 10 wt%) of the EPDM percolation threshold as well as a higher phase inversion concentration was observed. A combination of complementary techniques (SEM, selective extraction and rheological analysis) was successfully carried on in order to assess this (co)-continuity interval. Then, PP/EPDM blends with a co-continuous morphology were dynamically crosslinked in the RMX® using resole as a crosslinking agent. An original and specific procedure was developed for this purpose. Gel fraction close to 1 and significantly enhanced elastic properties after crosslinking confirmed the efficiency of this procedure. Finally, the dispersion of lamellar and conductive nanofillers (xGNPTM) in a polypropylene matrix was studied. Microstructural characterization by XRD and optical microscopy, rheological and electrical percolation thresholds (7 and 8 wt% of xGNP respectively) and corresponding aspect ratios (Af ~ 15) have shown no evidence of exfoliation.