An Introduction to Sourcing the Optimal Elastomer

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1 Produced by: Engineering 360 Media Solutions January 2017 An Introduction to Sourcing the Optimal Elastomer Sponsored by: The Hygenic Corporation Written by: Crystal Duncan Are you designing a new product that requires an elastomeric part? Or, perhaps you re sourcing a new elastomeric part for an existing application. Whatever the case, it can be confusing to try and select the correct elastomer for an application. For some, it may be difficult to even know where to start; aside from knowing that stretchy properties of some sort are needed. Each elastomer has different benefits and limitations that should be considered to select the optimal one for the specific industrial application. Almost two centuries of material research has yielded more than 30 elastomers (Hanhi, et al.), most of which can be classified into two main families thermosets and thermoplastics. However, each of these base elastomers can be compounded in different ways to produce elastomers all with very different properties. This exponentially increases the number of possible elastomers to choose from. So, it is beneficial to work with an elastomer expert that understands compounding to help you source the best possible material. To source the optimal elastomer, you will need to know the capabilities as well as any limitations of the material. When you start researching types of elastomers or before you start sourcing a rubber part, there are a few things to keep in mind. First, you ll want to know the property requirements of the finished part. Second, it will be helpful if you have a basic understanding of some material options you will need to know the capabilities as well as any limitations of the material. Lastly, you ll want to keep in mind that base elastomers can be custom compounded to suit specific needs, so try to speak to a compounder early in your design process. Establish the Property Requirements of the Elastomer Prioritizing the properties required from a material in an application helps narrow down the potential elastomer choices. There is no blanket or stop-gap elastomer that is great, or even adequate, in all aspects of performance. Instead, the two or three most important properties need to be identified with the understanding that some compromise on secondary properties might be necessary. Sponsored by: Here are some common properties that are typically associated with elastomers: Elongation: Ultimate elongation is how much an elastomer can stretch from its unloaded state before breaking, expressed as a percent. The ability of an elastomer to stretch and deform provides a great deal of toughness, allowing it to resist impacts and absorb high levels of energy before breaking. Rubbers actually become stronger or increase in elastic modulus at peak elongation. Recovery: This is a measurement of a material s ability to return to its original shape after the application of a deforming force. The two most common measurements used to define the recovery of an elastomer are tensile set and compression set. Tensile strength: The total amount of force needed to pull a material apart is known as ultimate tensile strength, typically represented in pascals (Pa) or pounds-force per square inch (psi). Yield strength is the point at which a material Produced by:

2 deforms irreversibly. Service temperature: The range of ambient temperatures in which the elastomer can be exposed and expected to retain all mechanical abilities. Durometer: The measurement of material hardness/ softness. Typically the Shore A or D scale is used for elastomers. Chemical resistance: The extent to which an elastomer retains its properties when exposed to specific chemicals. Weatherability: The suitability of a material in outdoor applications, where it will be exposed to climate extremes, precipitation, and UV light. The Two Main Categories of Polymers Thermosets and Thermoplastics The properties above will suggest which category of materials would be better suited to an application. The differences between the two categories of polymers begin with their basic chemical compositions. The raw materials of thermosets harden when exposed to heat and crosslink individual polymer chains into one large molecule, which is an irreversible process. If reheated, a thermoset material simply degrades. Thermoplastics, on the other hand, soften and begin to melt with sufficient heat but harden when cooled. They have reversible crosslinks that break down during thermal processing and then reform on cooling, which makes most of them recyclable. Many thermoplastics consist of two phases, or domains, with each phase providing specific properties, such as reinforcement or reversible crosslinking between chains. The difference between the two categories doesn t stop with their chemical compositions; there are also differences in the properties that each group possesses. For example, thermosets typically have better recovery and a higher tensile strength, up to three times more than a thermoplastic. Many thermosets and thermoplastics have comparable tear resistances, but certain thermoplastic materials have a wider range of hardnesses available. Thermosets typically have better thermal resistance than thermoplastics since the crosslinking of the polymer chains is thermally irreversible. These characteristics give thermosets excellent stability and integrity. Generally, thermosets are less expensive than thermoplastics. Now that the two main categories have been described, let s take a closer look at some elastomers that fall within each category and their individual properties. Some Common Thermoset Elastomers and Their Properties Natural Rubber (Natural Polyisoprene) Performance-wise, natural rubber (NR) is the epitome of elastomer materials with a 42% share of the entire elastomer market in 2013, per IHS Markit. It has the second best elasticity of any substrate; only butadiene rubber has a better modulus of elasticity. NR has an excellent service life due to its abrasion resistance and low internal friction when under load. It also has low hysteresis loss with consistent elongation and recovery. NR can withstand temperatures between F; anything less than -80 F and the rubber will become brittle. It should also be noted that there are some NR formulations that will start to stiffen at the -20 F range. As the product of a tree, NR contains impurities, such as dirt and minerals. Another impurity, protein, is a plant s selfdefense mechanism that triggers allergic reactions, but only in less than 1% of the United States population according to the American Latex Association. This has been dubbed a latex allergy, even though the reaction isn t to the latex itself. Not all latex products incite allergies and not all latex-free products are manufactured without allergens. NR is often the preferred elastomer for heavy-duty tires, vibration dampers, springs, bearings, sheets, films, tubes, and cords. It has minimal plastic deformation, making it optimal for sealing and gasketing NR is usually unsuitable for many outdoor applications, unless biodegradability is required. Synthetic Rubbers Most synthetic rubber development occurred in response to material shortages during World War II and in the years following to dampen pricing and availability fluctuations of NR from Southeast Asia. There are many types of man-made vulcanizates, but styrene-butadiene rubber (SBR) is the most common, the least expensive, and has the largest market. It is derived from petroleum, with the final product composed of 25% styrene and 75% butadiene. Overall, SBR behaves similarly to natural rubber with some small differences, such as better heat and petroleum resistance, a lower tensile strength, and less flexibility in low temperatures. Not surprisingly, SBR also finds its way into many tires, shoes, seal, and gasket Polybutadiene rubber is the second-most common synthetic rubber, although it is rarely used alone. Manufacturers often blend it with other elastomers, such as NR or SBR, to improve its elasticity, wear and abrasion resistance, and low temperature performance. Generally, polybutadiene rubbers are the most flexible of all elastomers. Tire manufacturing consumes the majority of polybutadiene that is produced, although it is also used for plastics reinforcement and golf ball cores. Isoprene rubber is another synthetic thermoset elastomer. Chemically, it bares the closest resemblance to NR, with high abrasion resistance and excellent recovery, though it is often more vulnerable to high temperatures. It has the added benefit of no impurities, such as the minerals, fatty acids, and allergenic proteins found in NR. Otherwise, isoprene rubber 2

3 is almost completely substitutable with NR and is used in many of the same Ethylene propylene diene monomer (EPDM) excels where many other rubbers lag: in exterior Due to this material s resilience to extreme temperatures ( F), and UV and weather resistance, it is optimal in many construction, marine, and nonpetroleum-based automotive The accompanying table represents values common for products made from the materials listed. Table 1. Data: MatWeb; Hanhi, et al. Some Common Thermoplastic Elastomers and Their Properties Thermoplastic elastomer (TPE) materials utilize thermal processing polymers as an essential constituent, so the final elastomer inherits its qualities, such as increased tensile strength, from an extensive range of plastic materials, which is a key advantage over thermosets. TPEs do not need an oven to cure, can be post-processed, and are usually recyclable. The properties of TPEs can be engineered by applying a wide range of polymer technologies, such as polymer blending, copolymerization with block phase formation, and liquid crystal formation. All of these processing advantages mean that parts made from TPEs can be more precisely formed. TPEs in the market today typically belong to one of six classes that together meet the majority of contemporary product design The first class, styrenic block copolymers (SBCs), is the largest class of TPEs, mostly because the stress-strain and hysteresis behaviors of SBCs most closely resemble those of a thermoset rubber. SBCs are notable for their excellent resistance to UV, water, and most chemicals, with the exception of petroleum products. This type of TPE has a high coefficient of friction, a soft, supple surface quality with durometer measurements usually in the Shore A range. SBCs are useful for road paving, roofing, and adhesive, sealing, and coating Thermoplastic polyurethanes (TPUs), the second class of TPEs, are comprised of three main chemical classes and are important because they are quite adaptable. TPE manufacturers are able to hone urethane chemistry for specific end-uses, giving it a broad range of specifications, including transparency. Polyester TPUs, one of the main chemical classes of TPUs, have superior abrasion resistance, mechanical performance, heat resistance, chemical resistance, adhesion strength, and processability. Polyether TPUs, another main chemical class of TPUs, are optimal for lower temperature environments, water resistance, and microbial resistance. The third class of TPEs, thermoplastic vulcanizates (TPVs), are blends of a thermoplastic material and a thermoset elastomer that work together but never unify into a single copolymer. 3

4 This provides the elastomeric properties of a thermoset elastomer with the processing of a thermoplastic. Excellent fatigue resistance is this material s most outstanding quality. TPVs also have good high-temperature performance and chemical resistance, as well as low compression and tension sets. Polyamide elastomers (PAEs), the fourth class of TPEs, are valued for their temperature operation range of F. The most well-known PAEs are nylons. As a whole, PAEs are low weight and have excellent flexibility and recovery. They are also chemical, impact, fatigue, and abrasion resistant. All of this adds up to an exceptional service life. PAEs are found in sporting goods, such as shoes, automotive components, fluid power equipment, and wire and cable insulation. The fifth class, thermoplastic olefins (TPOs), includes polyolefins, such as polypropylene or polyethylene. There are a wide variety of TPOs available today and they are quite durable. Many of them are scratch, UV, flame, and weather resistant. They can be formulated for lightweight and thinwall applications while retaining the impact and aesthetic qualities. All of these properties make them a common choice for roof membranes and automotive elastomers. Lastly, thermoplastic copolyesters (TPCs) have superb elasticity and recovery under low strain and are impervious to most oils and chemicals. TPCs are also suitable for use in high and low ambient temperature environments. They can include up to 60% bio-based raw materials, meaning that they are more sustainable than other TPEs. TPC materials are valuable for electrical connectors, especially those found outside or on automobiles. Their durability also makes them useful for material handling applications, such as conveyor belts. As before, the values in the accompanying table are representative of a material as a whole, and not for any singular application or product. Table 2. Data: MatWeb; Hanhi, et al.; ZNConsulting Conclusion After more than 175 years of advanced chemistry research and development, elastomers have become so numerous and ubiquitous that even engineers can have difficulty analyzing the base chemistries, performance, specifications, and standards of dozens of elastomers. Few individuals have the expertise to evaluate the complicated elastomer market. When sourcing your next elastomer part, start by establishing the part s property requirements. Then, narrow down material options based on those property requirements. For example, if you need something with excellent elasticity, you ll likely start in the natural or synthetic rubber categories. Lastly, keep in mind that once the desired properties have been established and a base elastomer is selected, the compound can be optimized, within its performance range, to suit your 4

5 specific needs. This can be accomplished by the addition of functional fillers or polymer blends, protectants, processing aids, and (in the case of thermosets) curing systems. Many people are unaware of the capabilities of custom compounders to design elastomers based on specific Too often, a designer or an engineer will leave the sourcing of the elastomer part for last, only to learn the elastomer they selected is not a suitable fit for various reasons. Selecting an elastomer should be addressed in the early design stages to avoid any sourcing or product design issues. Once you ve narrowed down your material options, contact a compounding specialist or manufacturer of that material to discuss your intended application and the suitability of that elastomer. THE HYGENIC CORP Home Avenue Akron, OH USA Phone: Fax: ENGINEERING 360 MEDIA SOLUTIONS 30 Tech Valley Drive, #102 East Greenbush, NY Tel: ABOUT THE HYGENIC CORPORATION For over 90 years, The Hygenic Corporation has been an innovative custom manufacturer of high quality elastomer tubing, sheeting and film for a variety of industries, such as medical, food and industrial. We specialize in low-durometer elastomers that exhibit excellent stretch and recover properties. Our research, development and engineering teams use this diverse insight to solve elastomer material challenges faced by manufacturers today. 5

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