Evaluation of the Salt Leaching Method for the Production of Ethylene Propylene Diene Monomer Rubber Foams

The thermomechanical behavior of ethylene propylene diene monomer (EPDM) foams produced with the salt leaching method has been investigated and compared with the behavior of EPDM foams obtained from conventional blowing agents. Moreover, the salt-leaching process has been optimized to minimize salt residues and the influence of different parameters (such as average particle size and particle size distribution) has been investigated. Scanning electron microscopy and density measurements highlighted that salt-leaching leads to the formation of open-cell porosity with cell dimensions of around 60 to 80 μm, while foams obtained with the two traditional foaming agents lead to closed-cell porosity. Compression set values indicate that the behavior of the foams produced with salt leaching are more similar to the unfoamed rubber, characterized by higher elasticity and low residual deformation. Two theoretical models were successfully applied to the compression curves (Mooney-Rivlin and Exponential-Logarithmic) and they highlighted the effect of foaming on the properties of EPDM rubber and in particular the higher chain extensibility obtained through the salt leaching foaming method.