Film formation process of natural rubber latex particles: roles of the particle size and distribution of non-rubber species on film microstructure

Natural rubber (NR) films from various mixing ratios of large- (LRP) and small rubber particles (SRP) were prepared through latex and solution casting methods. Film-forming behaviours of the resulting films were investigated by monitoring their surface characteristics using atomic force microscopy (AFM). When the SRP portion was higher, the surface of the latex-cast films was found to be smoother as smaller particles protruded out of the surface less than larger ones did. AFM phase micrographs revealed a hexagonal shape of packed rubber particles (RPs) of the LRP film, while the RPs in the other samples were sphere-like. After aging under ambient conditions, the packed RPs were flattened while retaining their RP boundaries, creating a supporting framework within the rubber matrix. On the contrary, when the rubber film was cast from a toluene solution, the characteristic of RP boundaries disappeared and became aggregates of the membrane components on the film surface. The latex-cast films performed much better in mechanical strength than the solution-cast films did due to the destruction of the supporting framework arisen from the non-rubber components at the RP boundaries of the solution-cast film. An inhomogeneous density distribution produced by the non-rubber aggregates in the latex-cast films was observed in small angle X-ray scattering measurements.