Exxon™ butyl rubber Exxon™ butyl rubber innertube technology manual Country name(s) 2 - Exxon™ butyl rubber innertube technology manual Exxon™ butyl rubber innertube technology manual - 3 Abstract Many bias and radial tires have innertubes. Radial truck tube-type tires are particularly common, and in many instances, such as in severe service, off-road applications, are preferred over tubeless radial tire constructions. The technology requirements for tubes for such tires is, in many respects, equally demanding when compared to that for the tire and wheel in the assembly. This manual has been prepared to describe how butyl rubber is important in meeting the demanding performance requirements of tire innertubes. Representative innertube compound formulations and compound properties are discussed along with typical processing guidelines of the compound in the manufacture of innertubes. Chlorobutyl rubber based compound formulations are also used in innertubes. Such innertubes show good heat resistance, durability, allow greater flexibility in compounding, and process equally well as regular butyl rubber tube compounds. An extensive discussion of bicycle tire innertubes has been included. Service conditions can range from simple commuting and recreation to high speed competitive sporting applications. Like automobile and truck tire innertubes, tubes for bicycle tires can thus have demanding performance requirements. Guidelines on troubleshooting provide a checklist for the factory process engineer to enhance manufacturing efficiency, high quality, and meet the end-product performance requirements. A set of references for further consultation conclude the manual. Exxon™ butyl rubber innertube technology manual - 3 1. Introduction ........................................................................................................................................................................................................................................................ 4 2. Innertube application requirements ....................................................................................................................................................................................... 6 3. Compounding of butyl and chlorobutyl rubber innertubes ....................................................................................................................... 8 4. Processing of butyl rubber innertube compounds ........................................................................................................................................... 14 5. Manufacture of butyl rubber innertubes ...................................................................................................................................................................... 20 6. Butyl rubber in bicycle innertubes ........................................................................................................................................................................................ 27 7. Heat resistant chlorobutyl rubber innertube ........................................................................................................................................................... 31 8. Guidelines for trouble shooting innertube processing and manufacturing ......................................................................... 35 9. Flaps......................................................................................................................................................................................................................................................................... 41 10. Summary ............................................................................................................................................................................................................................................................ 42 Appendix 1 ..............................................................................................................................................................................................................................................................43 Appendix 2 ..............................................................................................................................................................................................................................................................44 Appendix 3 ..............................................................................................................................................................................................................................................................45 11. References ........................................................................................................................................................................................................................................................ 46 4 - Exxon™ butyl rubber innertube technology manual Exxon™ butyl rubber innertube technology manual - 5 1. Introduction Butyl rubber (IIR) is a copolymer of isobutylene and a small Of the many properties of butyl rubber, low permeability to amount of isoprene (Figure 1)1,2. The primary attributes of gases is among the most important. Tables I and II illustrate butyl rubber are excellent impermeability for air barrier some of the properties of both butyl rubber and compounded performance and good flex fatigue properties. These butyl rubber, and compare the properties of butyl rubber to properties result from low levels of unsaturation in between other elastomers such as natural rubber, styrene butadiene the long polyisobutylene chain segments. Tire innertubes were rubber (SBR), and special purpose elastomers2,5. Tire inflation the first major use of butyl rubber, and this continues to be a pressure retention is now clearly recognized as a very significant market today. important parameter in maintaining tire operating performance, ensuring low tire rolling resistance and minimize Figure 1 vehicle fuel consumption, and ensuring long tire life by Butyl rubber: poly(isobutylene-co-isoprene)1,2,3 maintaining a proper tire tread footprint. The air retention properties of butyl rubber innertubes contributes toward attaining these properties. ISOBUTYLENE ISOPRENE Figure 2 CH CH3 3 Examples of butyl innertubes CH2 = C + CH2 = C CH = CH2 CH3 BUTYL RUBBER CH CH3 CH3 3 CH3 CH2 C CH2 C CH2 C = CH CH2 CH2 C CH CH3 CH3 n 3 In the most widely used manufacturing process for butyl elastomers, a slurry of fine particles of rubber dispersed in methyl chloride is formed from isobutylene and isoprene, in a reactor after Lewis acid initiation. The reaction is highly exothermic, and a high molecular weight can be achieved by controlling the polymerization catalyst level and temperature, which is typically between -90oC to -100oC. The most common polymerization process uses methyl chloride as the reaction Ref: ExxonMobil data. diluent and boiling liquid ethylene to remove the heat of 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 initiation and chain transfer reactions. Water and oxygenated organic compounds that can terminate the propagation step are minimized by purifying the feed systems. The chloro and bromo derivatives of butyl rubber were introduced commercially in the 1950s and early 1960’s. Due to butyl rubber’s low air and gas permeability, a large proportion of the world’s tube-type pneumatic tires, from bicycle and passenger car to truck and earthmover tires, rely on butyl rubber innertubes to retain air pressure. Figure 2 illustrates various types of butyl rubber innertubes2,3,4. Exxon™ butyl rubber innertube technology manual - 5 Table I Physical properties of butyl rubber2 Property Value Composition a Density, g/cm3 0.917 B 1.130 CBV Coefficient of volume expansion 560 x 10” BV (1/V) (V/T), K 460 x 10” CBV Glass-transition temperature, °C -75 to -67 B Heat capacity, Cp kJ/(kg.K)b 1.95 B 1.85 BV Thermal conductivity, W/(m.K) 0.130 BV 0.230 CBV Refractive index, np 1.5081 B (a) B = butyl rubber; BV = vulcanized butyl rubber; CBV = common stringent operating conditions such as long-distance vulcanized butyl rubber with 50 phr carbon black. travel at higher operating speeds, and heavier payloads under (b) To convert J to cal, divide by 4.184 difficult weather and temperature conditions. This manual provides a review of the current butyl rubber and chlorobutyl In addition, butyl rubber has good heat, oxygen and ozone rubber innertube technology. It also discusses basic resistance as well as good dynamic properties which enhance technology on compounding, processing, and troubleshooting. the long-term durability of innertubes. This is important given Table II Permeability of various elastomers to gases at 25ºC relative to natural rubber gum vulcanizates (=100)5 Elastomer He H2 O2 N2 CO2 Air Silicone Rubber 1070 2200 3300 1600 2700 Natural Rubber 100 100 100 100 100 100 EPDM 88 80 66 83 Polybutadiene 86 82 80 105 81 SBR 74 81 73 78 94 76 NBR (80/20 butadiene acrylonitrile) 55 51 35 31 48 33 NBR (73/27 butadiene acrylonitrile) 39 32 17 13 24 15 Polchloroprene 27 17 13 24 15 NBR (68/32 butadiene acrylonitrile) 32 24 10 7.5 14 8.5 Butyl Rubber 27 15 5.6 5.0 4.0 4.8 Note: 1. Lower rating is better. 2. Permeability at 25°C. 3. See Appendix 1 for abbreviations. 6 - Exxon™ butyl rubber innertube technology