Nitrile Rubber Applications

Nitrile rubbers material properties make it an excellent solution for sealing applications. The popularity of nitrile material results from its excellent resistance to petroleum products and its ability to be compounded for service of temperatures up to 250F. With these temperature resistances, the right nitrile rubber compounds can withstand all but the most severe automotive applications. Other applications that benefit from nitrile rubbers properties which can be custom compounded and molded include:

Oil resistant applications Low temperature applications Automotive, marine and aircraft fuel systems Nitrile roll covers Hydraulic hoses Conveyer belting Nitrile tubing

Nitrile Rubber Chemistry and Compounding

The production of nitrile material takes place through an emulsion polymerization system. This emulsion process begins when the monomers (butadiene and acrylonitrile) are introduced along with water, emulsifier/soap, radical generating activator and other ingredients into polymerization vessels. The result of this emulsion process is a polymer latex yield that is coagulated using various materials such as calcium chloride and aluminum sulfate to form the crumb rubber that is then dried and compressed into bales. Like most other unsaturated thermoset elastomers, Nitrile compound formulations require added ingredients and further processing to be rendered useful in different applications. The additional additives typically include plasticizers, reinforcement fillers, protectants, and vulcanization packages. The differing amount of additive materials and levels of acrylonitrile will determine the differences in the various compounds that can be formulated. Timco rubber has the capabilities to compound nitrile rubber specifically to your individual needs. We are able to vary polymerization temperatures to create "hot" and "cold" polymers. Also, by varying the Acrylonitrile and butadiene ratios we can specifically formulate your nitrile compound for the necessary fuel resistance and low temperature requirements. Nitrile elastomer compounds can also be hydrogenated in order to reduce the chemical reactivity of the polymers backbone, thereby significantly improving the materials heat resistance.

Acrylonitrile Content
By adjusting the acrylonitrile (ACN) content in a nitrile compound, a number of different results can be achieved. Because of its polarity, the ACN level determines several key properties of the nitrile material such as; oil and solvent resistance, abrasion resistance, and also low-temperature flexibility/glass transition temperature. A higher concentration of ACN will provide improved solvent, abrasion and oil resistance along with a higher glass transition temperature. The table below summarizes properties common to many conventional NBR polymers. The direction of the arrows signifies an improvement in the values. Nitrile Rubber with Lower Acrylonitrile Content Processability Cure Rate w/Sulfur Cure system Oil/Fuel Resistance Compatibility w/Polar Polymers Air/Gas Impermeability Tensile Strength Abrasion Resistance Heat-Aging Nitrile Rubber with Higher Acrylonitrile Content

Cure Rate w/Peroxide Cure System Compression Set Resilience Hysteresis Low Temperature Flexibility

General Types of Nitrile Rubber

Hot Nitrile Rubber Hot NBRs are polymerized at temperatures ranging from 30 to 40C in a process that yields highly branched polymers. This branching supports good tack and strong bonding in adhesive applications. By processing this kind of polymer and creating a physically entangled structure, the end product also exhibits a significant improvement in hot tear strength when compared to a cold-polymerized counterpart. Hot NBR has a natural resistance to flow, making it an excellent candidate for compression molding and sponge applications. Other applications where Hot Nitrile Rubber proves useful include thin walled or complex extrusions where shape retention is important. Cold Nitrile Rubber Depending on the balance of linear-to-branched configuration desired, cold nitrile is polymerized at temperatures ranging from 5 to 15C. These lower polymerization temperatures will yield more linear polymer chains. The reactions are conducted in processes known as continuous, semi-continuous, or batch polymerization. Cold NBR compounds span a wide variety of compositions. They can contain Acrylonitrile in ranges from 15% to 51%. The Mooney values of these Nitrile materials range from a very tough 110 to pourable liquids, with 20-25 as the lowest practical limit to maintain a solid material. These Nitrile compounds are made with an array of chemical compositions, coagulants, molecular weight modifiers, stabilizers and emulsifier systems. Third monomers can also be added to the polymer background to provide advanced performance; with each variation of the compound providing a specific function to the overall Nitrile material. Crosslinked Hot Nitrile Rubber Crosslinked Hot NBRs are branched polymers that become further cross-linked through the addition of a di-functional monomer. These nitrile rubber compounds are typically used in molded parts to provide sufficient molding forces, or back pressure, in order to eliminate any trapped air. An additional use is to provide increased shape retention or dimensional stability for extrusion. As a result, crosslinked hot nitrile proves to be more efficient in the extrusion and vulcanization of intricate shaped parts. These NBRs will also add impact resistance, dimensional stability and flexibility for PVC modification.

Product Description
Butyl rubber has exceptionally low gas and moisture permeability and outstanding resistance to heat aging, weather, ozone, chemical attack, flexing, abrasion and tearing. It is resistant to phosphate ester based hydraulic fluids, and has excellent electrical insulation performance. Butyl is not recommended for use when in contact with petroleum oils and fluids. Butyl performs well for such applications as:

Vibration grommets Shock mounts Motor mounts

Properties of Butyl Rubber

Butyl Rubber is a copolymer of isobutylene and a small amount of isoprene. The isoprene units in butyl contain a double bond that provides a site for cross linking during vulcanization and are located randomly in the polymer chain. Butyl Rubber: poly(isobutylene-co-isoprene)

The primary attributes of butyl rubber include good flex fatigue properties and excellent impermeability for air barrier performance. These properties are the result of low levels of unsaturation in between the long polyisobutylene chain segments. Common Names ASTM D-2000 Classification Chemical Definition General Characteristics Durometer Range (Shore A) Tensile Range (P.S.I) Elongation (Max %) Compression Set Resilience Rebound Abrasion Resistance Tear Resistance Solvent Resistance Oil Resistance Low Temperature Usage (F) High Temperature Usage (F) Aging Weather Sunlight Adhesion to Metals 40-90 500-3000 850 Fair to Good Fair Fair Good Poor Poor -10 to -60 Up to 250 Excellent Good Butyl AA, BA Isobutylene Isoprene

Comment Butyl Rubber is impermeable to most common gasses and has a good resistance to the effects of sunlight and ozone. Butyl is normally satisfactory when exposed to vegetable and animal oils as well as oxidizing chemicals. It is not recommended to use Butyl Rubber with petroleum solvent, coal tar or aromatic hydrocarbons.

Advantages of Butyl Rubber

Flexibility Air tight and gas impermeable (a property unique to butyl rubbers) Low glass transition temperature

Good ozone resistance Displays high damping at ambient temperatures Good weathering, heat, and chemical resistance Good vibration damper Biocompatible

Butyl Rubber Processing

Butyl rubber must be compounded and vulcanized to yield useful, durable end use products for most applications. Different grades of butyl are developed based on specific property needs. Because of this, differing grades will show a range of molecular weights, unsaturation and cure rates. Both the end use properties and the processing equipment used will be important factors in determining the right grade of butyl rubber in each specific application. Our selection of the proper fillers, stabilizers, processing aids and curatives will play a vital role in the ability of the butyl compound to meet the end product specifications and requirements. The most widely used manufacturing process for butyl elastomers involves Lewis acid initiation in a reactor to form a slurry of fine rubber particles dispersed in methyl chloride from isobutylene and isoprene. The reaction that takes place is highly exothermic and, by controlling the polymerization catalyst level and temperature (between -90C to -100C), a high molecular weight can be achieved. In this polymerization process, methyl chloride is used as the reaction diluent while boiling liquid ethylene is used to remove the heat of the reaction and maintain the low temperature needed. The final molecular weight of the butyl rubber is determined primarily by controlling the catalyst level, temperature, and the initiation and chain transfer reactions.

Butyl Rubber's Low Gas Permeability

Among other hydrocarbon elastomers, butyl rubber shows very good permeability to air and other gases. Permeation of gas through a polymeric membrane involves the gas dissolving in the polymer at the high pressure side, diffusion through the membrane, and subsequent evaporation at the low pressure surface. The rate of gas transfer through the membrane, or permeability, is determined by the solubility and diffusitivity of the gas. The table below illustrates the permeability of butyl rubber in comparison to other elastomers such as natural rubber, styrene butadiene rubber (SBR), EPDM, and other special purpose elastomers. Elastomer Silicone Rubber Natural Rubber EPDM Polybutadiene SBR NBR (80/20 butadiene acrylonitrile) NBR (73/27 butadiene acrylonitrile) Polychloroprene NBR (68/32 butadiene acrylonitrile) Butyl Rubber He 100 74 55 39 32 27 H2 1070 100 86 81 51 32 27 24 15 O2 2200 100 88 82 73 35 17 17 10 5.6 N2 3300 100 80 80 78 31 13 14 7.5 5 CO2 1600 100 66 105 94 48 24 20 14 4 Air 2700 100 83 81 76 33 15 15 8.5 4.8

Permeability of Various Elastomers to Gases at 25C Relative to Natural Rubber Gum Vulcanizates (=100)5
Source: Exxon Mobile Chemicals Note: Lower Rating is better

Heat Resistance
Rubber products made from butyl material prove to be more durable than those made with natural rubber as butyl rubber parts are better able to retain their properties at high temperatures.

Tear Strength
The molecular structure of butyl rubber allows it to enjoy a better aged tear strength retention when compared to natural rubber.

Source: ExxonMobil Company

Aging Resistance
When looking at the effects of aging, exposure to oxygen and ozone in the atmosphere will cause natural rubber to oxidize, deteriorate, and eventually crack. Because of the materials good aging resistance, butyl rubber parts will have a longer life span without the need for additional antioxidant and antiozonants systems. In the example below, both butyl rubber and natural rubber parts where stretched by 20% and exposed for 72 hours at 40C and 50 pphm of ozone. Aging of Natural Rubber (NR) and Butyl Rubber (IIR)

Source: ExxonMobil Company

Butyl Rubber Applications

Sealant for rubber roof repair Tubeless tire liners Inner tubes Stoppers for glass bottles, medicine bottles and pharmaceuticals Used in sealants and adhesives Butyl O Rings Pond Liners Tank Liners Construction sealants, hoses, and mechanical goods

Body Mounts and Sound Damping

The unique combination of high damping, barrier properties, resistance to ozone and heat aging make butyl products an ideal choice for many automotive non-tire applications. One of the largest applications of butyl rubber parts includes vibration control applications and dynamic parts including body mounts. Butyl rubber is widely used in these applications because of its high damping, fast reversionresistant cures and its excellent aging properties, especially in respect to hot flex fatigue.

Petroleum oils can be used in rubber, either as a process aid or as an extender. When less than ten parts of oil has been added per hundred parts of rubber, the oil is considered to be a process aid. When the addition rate is above that level, the petroleum oil is considered to be an extender, lowering the value of the product. If NR contains oil as an extender, it is called oil-extended NR (OENR). In tyres, OENR can impart high skid resistance on wet or icy roads, low rolling resistance and resistance to both wear and groove cracking. Oil can be added either to rubber in the form of latex or to dry rubber.