1

Ethylene‐Propylene Rubbers & Elastomers (EPR / EPDM)

PROPERTIES AND APPLICATIONS
Ethylene-propylene rubbers & elastomers (also called EPDM and EPM) continue to be one of the most widely used
and fastest growing synthetic rubbers having both specialty and general-purpose applications. Polymerization and
catalyst technologies in use today provide the ability to design polymers to meet specific and demanding application
and processing needs. Versatility in polymer design and performance has resulted in broad usage in automotive
weather-stripping and seals, glass-run channel, radiator, garden and appliance hose, tubing, belts, electrical
insulation, roofing membrane, rubber mechanical goods, plastic impact modification, thermoplastic vulcanizates and
motor oil additive applications.

Ethylene-propylene rubbers are valuable for their excellent resistance to heat, oxidation, ozone and weather aging
due to their stable, saturated polymer backbone structure. Properly pigmented black and non-black compounds are
color stable. As non-polar elastomers, they have good electrical resistivity, as well as resistance to polar solvents,
such as water, acids, alkalies, phosphate esters and many ketones and alcohols. Amorphous or low crystalline grades
have excellent low temperature flexibility with glass transition points of about minus 60°C.

Heat aging resistance up to 130°C can be obtained with properly selected sulfur acceleration systems and heat
resistance at
160°C can be obtained with peroxide cured compounds. Compression set resistance is good, particularly at high
temperatures,
if sulfur donor or peroxide cure systems are used.

These polymers respond well to high filler and plasticizer loading, providing economical compounds. They can
develop high tensile and tear properties, excellent abrasion resistance, as well as improved oil swell resistance and
flame retardance. A general summary of properties is shown in Table 1 below.

Table 1: Properties of Ethylene-Propylene Elastomers

Polymer Properties Mooney Viscosity, ML 1+4 @ 5-200+
125°C

Ethylene Content, wt. % 45 to 80 wt. %

Diene Content, wt. % 0 to 15 wt. %

Specific Gravity, gm/ml 0.855-0.88 (depending on polymer

composition)

Vulcanizate Hardness, Shore A Durometer 30A to 95A

Properties*

Tensile Strength, MPa 7 to 21

Elongation, % 100 to 600

Compression Set B, % 20 to 60

Useful Temperature Range, °C -50° to +160°

Tear Resistance Fair to Good

 2

Abrasion Resistance Good to Excellent

Resilience Fair to Good (stable over wide temp. ranges)

Electrical Properties Excellent

* Range can be extended by proper compounding. Not all of these properties can be obtained in one compound.

CHEMISTRY AND MANUFACTURING PROCESSES

Ethylene-propylene rubbers use the same chemical building blocks or monomers as polyethylene (PE) and
polypropylene (PP) thermoplastic polymers. These ethylene (C2) and propylene (C3) monomers are combined in a
random manner to produce rubbery and stable polymers. A wide family of ethylene-propylene elastomers can be
produced ranging from amorphous, non-crystalline to semi-crystalline structures depending on polymer composition
and how the monomers are combined. These polymers are also produced in an exceptionally wide range of Mooney
viscosities (or molecular weights).

The ethylene and propylene monomers combine to form a chemically saturated, stable polymer backbone providing
excellent heat, oxidation, ozone and weather aging. A third, non-conjugated diene monomer can be terpolymerized
in a controlled manner to maintain a saturated backbone and place the reactive unsaturation in a side chain available
for vulcanization or polymer modification chemistry. The terpolymers are referred to as EPDM (or ethylene-
propylene-diene with “M” referring to the saturated backbone structure). An EPDM polymer structure is illustrated
in Figure 1. The ethylene-propylene copolymers are called EPM.

Figure 1 Structure of EPDM containing ENB

The two most widely used diene termonomers are primarily ethylidene norbornene (ENB) followed by
dicyclopentadiene (DCPD). Each diene incorporates with a different tendency for introducing long chain branching
(LCB) or polymer side chains that influence processing and rates of vulcanization by sulfur or peroxide cures. These
characteristics are summarized in Table 2.
 3

Table 2: Cure-Site Diene Termonomers in Ethylene-Propylene Elastomers

Long Chain 
Termonomer  Cure & Property Features  Branching 
 Fastest and Highest State 
ENB   of Cure   Low to Moderate  
 Good Tensile  
 Good Compression Set 
Resistance  

DCPD    Slow Sulfur Cure   High  

 Good Compression Set 
Resistance  

Specialized catalysts are used to polymerize the monomers into controlled polymer structures. Since their
introduction, ethylene-propylene elastomers have used a family of catalysts referred to as Zeigler-Natta named after
their initial developers. Improvements in catalysts and processes have provided increased productivity while
maintaining control of polymer structure. Most recently
a new family of catalysts, referred to as metallocene catalysts, has been developed and are in commercial use.

There are three major commercial processes, solution, slurry (suspension) and gas-phase, for manufacturing
ethylenepropylene rubbers. The manufacturing systems vary with each of the several producers. There are
differences in the product grade slates made by each producer and process, but all are capable of making a variety of
EPDM and EPM polymers. The physical forms range from solid to friable bales, pellets and granular forms and oil
blends.

The solution polymerization process is the most widely used and is highly versatile in making a wide range of
polymers. Ethylene, propylene, and catalyst systems are polymerized in an excess of hydrocarbon solvent.
Stabilizers and oils, if used, are added directly after polymerization. The solvent and un-reacted monomers are then
flashed off with hot water or steam, or with mechanical devolatilization. The polymer, which is in crumb form, is
dried with dewatering in screens, mechanical presses or drying ovens. The crumb is formed into wrapped bales or
extruded into pellets. The high viscosity, crystalline polymers are sold in loosely compacted, friable bales or as
pellets. The amorphous polymers grades are typically in solid bales.

The slurry (or suspension) process is a modification of bulk polymerization. The monomers and catalyst system are
injected into the reactor filled with propylene. The polymerization takes place immediately, forming crumbs of
polymer that are not soluble in the propylene. Slurry polymerization reduces the need for solvent and solvent
handling equipment, and the low viscosity of the slurry helps to control temperature and handle the product. The
process is not limited by solution viscosity, so high molecular weight polymer can be produced without a production
penalty. Flashing off the propylene and termonomer completes the process before forming and packaging.

Gas-phase polymerization technology was recently developed for the manufacture of ethylene-propylene rubbers.
The reactor consists of a vertical fluidized bed. Monomers and nitrogen in gas form along with catalyst are fed to the
reactor and solid product is removed periodically. Heat of reaction is removed through the use of the circulating gas
that also serves to fluidize the polymer bed. Solvents are not used eliminating the need for solvent stripping,
washing and drying. The process is also not limited by solution viscosity, so high molecular weight polymer can be
produced without a productivity penalty.

Continuous injection of a substantial amount of carbon black used as a partitioning aid is necessary to prevent the
polymer granules sticking to each other and to reactor walls. Products are made in a granular form to enable rapid
mixing.
 4

PROCESSING AND VULCANIZATION

The processing, vulcanization and physical properties of ethylene-propylene elastomers are largely controlled by the
characteristics of ethylene content, diene content, molecular weight (or Mooney viscosity) and molecular weight
distribution. For example, decreasing ethylene content decreases crystallinity and associated properties such as
hardness and modulus.
General polymer features in rubber compounding are summarized in Table 3.

Table 3 – General Features of Ethylene-Propylene Elastomers

Characteristics High Low

Ethylene Content   Good Green Strength   Fast Mixing  
Flow at High Extrusion Temperatures  Low Temperature Flexibility  
High Tensile Strength, Modulus   Low Hardness and Modulus  
High Loading (Reduced Cost)   Calendering and Milling  
Diene Content   Cure Degree and Fast Rate   Scorch Resistance  
Acceleration Versatility   High Heat Stability  
Good Compression Set   Low Hardness and Modulus  
High Modulus, Low Set
Molecular Weight Good  Tear  Modulus 
Tensile 
High Loading and Oil Extension High  High Loading and Oil Extension High 
Extrusion Rates  Extrusion Rates 
Good Green Strength   Good Calendering  
Collapse Resistance   Low Viscosity, Scorch Resistance  
MWD   Overall Good Processing   Low Die Swell  
Extrusion Feed and Smoothness   Fast Extrusion Rate  
Collapse Resistance   High Cure  
Good Calendering and Milling   Good Physicals  

CONCLUSION
Ethylene-propylene elastomers are one of the most versatile, fastest growing and interesting synthetic rubber
polymers. Excellent resistance to heat, oxidation, ozone and weather aging are expected to provide continued value
in demanding automotive, construction, and mechanical goods applications. Current and emerging advanced
polymerization and catalyst technologies also provide the ability to design polymers to meet application and
processing needs that are important to meeting the ever-increasing demands for product quality, uniformity and
performance.