Effects of BET Surface Area and Silica Hydrophobicity on Natural Rubber Latex Foam Using the Dunlop Process

To reinforce natural rubber latex foam, fumed silica and precipitated silica are introduced into latex foam prepared using the Dunlop process as fillers. Four types of silica, including Aerosil 200 (hydrophilic fumed silica), Reolosil DM30, Aerosil R972 (hydrophobic fumed silica), and Sipernat 22S (precipitated silica), are investigated. The latex foam with added silica presents better mechanical and physical properties compared with the non-silica foam. The hydrophobic nature of the fumed silica has better dispersion in natural rubber compared to hydrophilic silica. The specific surface area of silica particles (BET) also significantly influences the properties of the latex foam, with larger specific surface areas resulting in better dispersity in the rubber matrix. It was observed that exceeding 2 phr led to difficulties in the foaming process (bulking). Furthermore, higher loading of silica also affected the rubber foam, resulting in an increased shrinkage percentage, hardness, compression set, and crosslink density. The crosslink density increased from 11.0 ± 0.2 mol/cm³ for non-silica rubber to 11.6 ± 0.6 mol/cm³ for Reolosil DM30. Reolosil DM30 also had the highest hardness, with a hardness value of 52.0 ± 2.1 IRHD, compared to 45.0 ± 1.3 IRHD for non-silica foam rubber and 48 ± 2.4 IRHD for hydrophilic fumed silica Aerosil 200. Hydrophobic fumed silica also had the highest ability to return to its original shape, with a recovery percentage of 88.0% ± 3.5% compared to the other fumed silica. Overall, hydrophobic fumed silica had better results than hydrophilic silica in both fumed and precipitated silica.