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Ecologically Safe Water-based Chlorosulfonated Polyethylene

Ecologically Safe Top quality synthetic rubber with the same properties as the most expensive primium synthetic rubber causing no pollution and less expensive then the cheapest currently available rubber.

Based on Aqueous Dispersion of Chlorine -Sulphonated-Polyethylene

Chlorosulfonated polyethylene (CSPE) is a thermoset material manufactured mainly by Du Pont - Dow Elastomers, S. A., of Geneva, Switzerland (hereafter DPD). Elastomers (natural and synthetic rubbers) consumption in the world tops 18 million tons annually. CSPE is a premium synthetic rubber, relatively expensive and of superior quality. World CSPE consumption is only a small fraction of the elastomers’ total, presently at about 37,000 tons annually.

The project is based on previous research of the inventor in the field of statistical modeling of processes of formation of various branched crosslinked structures. CSPE (Chloro-Sulphonated Polyethylene) is hardened in a water suspension by Mannich alkalis. The resulting synthetic rubber has all the advantages of CSPE, but is clean of the organic solution which is poisonous. In addition, Company proved that low molecular weight PE may also be used, thus considerably reducing the presently high cost of the raw material, CSPE.
The main import of the innovative process is a very efficient, clean and environmentally friendly production process of CSPE dispersed in water.

STATE OF PRESENT ART

CSPE is a thermoset material manufactured mainly by Du Pont - Dow Elastomers, S. A., of Geneva, Switzerland (DPD). CSPE is made by adding chloride and sulfonyl groups to polyethylene. This modification changes the stiff plastic into a rubbery polymer which can be crosslinked in a variety of ways. Like PVC and XLPE, CSPE is a mechanical mixture of ingredients that may contain polymer, fillers, modifiers and crosslinking agents. The quantity and type of each ingredient affects the final physical and electrical properties of the insulation.
DPD sells various density CSPE under the commercialname Hypalon®. DPD's only production facility is in Beaumont, Texas. It produces CSPE at close to its maximal capacity, which is approximately 35,000 tons per annum. Other producers such as Tosoh Corporation, Japan, have other names for it. The Tosoh Corporation produces approximately 2,000 tons annually.
Paint producers, electric cable producers, etc., use the CSPE to create products for a variety of industries, including automobile, construction, and maritime. In the case of coatings for the construction industry, for instance, CSPE is solved in an organic solvent such as toluene and xylene. The solution used is volatile and toxic because of the solvents, therefore very unfriendly to the environment and unsafe to use.

MARKET

Elastomers (natural and synthetic rubbers) consumption in the world tops 18 million tons annually. CSPE is a premium synthetic rubber, relatively expensive and of superior quality. World CSPE consumption is only a small fraction of the elastomers' total, presently at about 37,000 tons annually. CSPE was always considered a prime material the spread of which was severely limited by high cost of production and environmental drawbacks. (refer, for instance, to the Montreal Protocol)
CSPE sells for ca. US $5 per kilogram. Each one-dollar in CSPE creates a six-fold street value market. Consequently, the annual sales of CSPE consist of a value of US $185 millions that translate to a street value market of more than US $1.1 billion. The market however could be much larger if the price could be brought down to competitive levels and the environmental drawbacks resolved.

FEASIBILITY PROVEN, PATENT PENDING

Company has produced several sample coatings to prove feasibility. Mechanical tests performed on samples proved products are as good as their predecessors solved in organics.
A patent application has been submitted in the US.

APPLICATIONS

For use as anti-corrosion hydro-insulating binder or coating material in the following industries:
Construction: linings for potable water reservoirs, sheet roofing, adhesives
Aircraft: jacketing and insulation for wire and cable
Naval and Maritime: protective and corrosion resistant applications
Automotive: high-temperature timing belts, power steering pressure hoses, gaskets, spark plug boots

The mission is to develop, produce and market ecologically friendly compounds based on chlorine-sulfonated-polyethylene (CSPE) hardened by aqueous solutions of Mannich alkalis.

The use of Mannich Alakalis (MA) as a CSPE structure component produces a vulcanized net of saturated polymer. Mannich alkalis are non-toxic, not volatile and are characterized by excellent solubility in aqueous and organic solvents.

Various types of CSPE (low and high molecular weight) and MA vulcanizing agents were investigated, the optimized results being binders and coatings for various applications.

The development is based on previous research of the founder in the field of statistical modeling of processes of formation of various branched cross-linked structures.