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Aircon elastomers
Aircon elastomers
Aircon elastomers
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dynamic laws. The refrigerant then ab- Hoses for use with refrigerants under tures and explosive decompression stu-
sorbs heat from the surroundings, and pressure should have a high modulus dies carried out with new refrigerant sys-
evaporates in the evaporator (8) and to provide good resistance to expansion tem demonstrated a need for other elas-
again enters the compressor (1). and good compression set to provide tomers and other compounding princi-
The development of rubber parts for good sealing under clamping conditions ples than those used for air-conditioning
air-conditioning systems, such as seals at the various fittings. systems based on CFCs.
and hoses, has been one of the most Fluid resistance tests, permeability stu- The purpose of this work was to devel-
challenging areas in the European rubber dies, ageing studies at higher tempera- op a halobutyl formulation for an inner
industry. At the beginning of 1990, there
were only a few rubber companies in Eu-
rope capable of offering rubber hoses for
air-conditioning systems. By 1997 more
than 30 were actively involved in various
development projects. With increased
competition and a desire to ensure a pre-
sence in this growing market, some com-
panies have caused a considerable de-
crease in price of these products and
as a consequence, other companies
opted to pull out of this business, as
they judged it unprofitable.
In the 1990s, the automotive industry is
facing historic change caused by legisla-
tion based upon the Montreal protocol,
which governs the phase-out of chloro-
fluorocarbons (CFCs) for use as automo-
tive refrigerants. These reactive chlorine-
containing chemicals contribute to ozone
breakdown in the upper atmosphere,
causing an increase in global warming.
To combat this environmental problem,
the automotive industry has selected a
new refrigerant, R-134a. The change of
the refrigerant required a compatible lu- Figure 2. Relative Permeation Rates for R-134a (80 8C)
bricant. Polyalkylene glycol (PAG) was se-
lected for this purpose. The operating
temperature range for the new refrigerant
system has increased to 132 ± 138 8C in
comparison with the temperature range
of 120 ± 127 8C valid for the previous re-
frigerant system based on CFC (R12)
and mineral oil as lubricant. The change
in the refrigerant system, lubricant and
the temperature has led to a new ap-
proach to compounding of rubber com-
ponents for air-conditioning systems, all
around the world.
The key product characteristics to be
designed into seals and hoses for air-
conditioning systems are:
* Low permeability and resistance to
R-134a
* Resistance to the lubricant (PAG)
* Resistance to operating temperatures
from 30 8C to over 150 8C
* Good compression set
* Good resistance to dynamic stress, vi-
brations and pressure up to 30 bars
* Low noise development. Figure 3. Relative Permeation Rates for R-12 (3:5 105 Pa at 80 8C)
component is usually a halogenated butyl many air-conditioning hose manufac- Halogenated butyl rubber vulcanisates
rubber because of its low permeability to turers around the world as the base poly- have the lowest permeability to gases
R-134a. This type of hose had excellent mer for inner tubes. The use of haloge- and vapours, as well as the lowest ab-
permeation resistance. This approach nated butyl rubbers for inner tubes is sorption of water and many other chemi-
was common in the USA, however, it more economical in comparison with cals. Air permeability, as a function of
did not meet European expectations. other systems available, as discussed temperature, of a number of elastomers
The manufacture of these hoses is diffi- above. is shown in Figure 5. The vulcanisates
cult and expensive. The hoses are too ri- Halogenated butyl rubbers are haloge- contain 50 phr SRF carbon black and
gid and generate noise particularly at low- nated copolymers of isobutene with small no plasticiser. The air permeability of ha-
er temperatures. European hose manu- amounts of isoprene. The isoprene is in- logenated butyl rubber vulcanisates is
facturers generally adopted an all-elasto- corporated to provide double bonds, comparable with that of NBR vulcani-
mer hose construction, with an inner tube which allow the rubber to be vulcanised sates and, in the case of NBR with a
based on halogenated butyl rubber or with sulphur and other vulcanising high ACN content (40 ± 50 %), is almost
HNBR, in a few cases with a paper-thin agents. The presence of a halogen, either identical.
layer of polyamide which provides the bromine or chlorine, provides a higher
permeation barrier. The hose cover is vulcanisation activity and versatility. Halo-
Compounding ingredients
based on a variety of elastomers, such genated butyl rubbers are readily covul-
as ethylene-propylene rubber (EPDM), canised with highly unsaturated elasto- Fillers
chloroprene rubber (CR), halogenated mers, such as NR, SBR, NBR, CR,
butyl rubber (BIIR, CIIR) or ethylene-vinyl EPDM etc. Carbon black was selected as the reinfor-
acetate (EVM). A similar approach was Many of the properties of halogenated cing agent. Trials were also made with
adopted by some Japanese hose manu- butyl vulcanisates are virtually identical, blends of carbon black and mineral fillers,
facturers [3] who proposed a hose based regardless of the halogen employed. Be- such as calcined clay, barium sulphate
on a butyl inner tube and a halogenated cause of the lower C-Br bond energy, the and silane-treated talc [4]. The later
butyl cover. cure sites in bromobutyl are more reac- was used because of its platy structure,
tive, resulting in faster cures, greater which contributes to even lower perme-
cure versatility and better covulcanisation ability of halogenated butyl vulcanisates.
Rubber Compounds for Inner
with general purpose elastomers. Moreover, silane-treated talc covulca-
Tubes
Halogenated butyl rubbers can be vul- nises with halogenated butyl rubbers
canised with a small amount of zinc through its silane groups, giving vulcani-
The Base Polymers
oxide, or even without, and require a sates with a higher modulus than with any
Halogenated Butyl Rubbers very low level of other vulcanisation other mineral filler. The level of filler was
agents. The vulcanisate properties are tested for its effect on processing proper-
Because of their excellent permeation re- very similar, regardless of the halogen ties and physical properties.
sistance to the new refrigerant R-134a, used. However, as far as the compres-
high damping of low frequency vibra- sion set is concerned, chlorobutyl gener- Plasticisers
tions, excellent low temperature proper- ally gives lower values in comparison to
ties and excellent heat ageing, haloge- bromobutyl. Plasticisers were not used in our studies
nated butyl rubbers are considered by in order to eliminate the risk of extraction
Figure 6. Compression set (P-VW 3307) (Chlorobutyl Compounds) Figure 7. Compression set (DBL-5555) (Chlorobutyl Compounds)
by the refrigerant and to minimise the per- Table 1. Chlorobutyl Liner Compounds for Air Conditioning Hoses
meability of the vulcanisates. If necessary,
1289 A 761 762 763 764 765 766 767
small amounts of processing aids can be
used, preferably paraffinic oils, low Chlorobutyl rubber 1240 100 100 100 100 100 100 100
Stearic acid 1,0 1,0 1,0 1,0 1,0 1,0 1,0
molecular weight polyethylene (e. g. Carbon black N 772 70,0 70,0 70,0 70,0 70,0 70,0 70,0
AC 617) or low molecular weight polybu- Zinc oxide active 5,0 5,0 5,0 5,0 5,0 5,0 5,0
tene (Indopol H-300, Hyvis 100, 200 etc.) Phenolic resin 5,0 ± 5,0 ± ± ± ±
Poly-alkylphenoldisulphide 1,0 1,0 ± ± ± ± ±
as well as stearic acid. The following fac- ZDEC ± ± ± ± 1,5 ± ±
tors have to be considered when select- Vultac 710 ± ± 1,0 1,0 ± ± ±
ing the plasticisers: compatibility with the TMTD ± 0,25 ± 0,25 ± 1,5 ±
base polymer, plasticising efficiency and MBTS ± 1,5 ± 1,5 ± ± ±
Magnesium oxide ± 0,5 ± 0,5 0,5 ± 0,5
extractability by the refrigerant DTDM ± ± ± ± ± 2,0 ±
DBU ± ± ± ± ± ± 4,5
Antioxidants Total, phr 182,0 179,25 182,0 179,25 178,0 179,0 181,0
Table 2. Bromobutyl Compounds for Inner Tube for Air Conditioning Hoses
Compound: 1289 A 791 A 792 A 793 A 794 A 795 A 796 A 797 A 798
Bromobutyl 2030 100,0 100,0 100,0 100,0 100,0 100,0 100,0 100,0
Stearic acid 1,0 1,0 1,0 1,0 1,0 1,0 1,0 1,0
Carbon black N 772 70,0 70,0 70,0 70,0 70,0 70,0 70,0 70,0
Zinc oxide active 5,0 5,0 5,0 5,0 5,0 5,0 5,0 5,0
Phenolic resin 5,0 ± ± ± ± ± ± ±
Poly-alkylphenoldisulphide ± ± 2,0 ± ± ± ± ±
ZDEC ± ± ± 2,0 ± ± ± ±
TMTD ± 0,25 ± ± 1,5 ± ± ±
MBTS ± 1,5 ± ± ± ± ± ±
DBU ± ± ± ± 2,0 ± 5,0 7,0
MMBI ± ± ± ± ± 2,0 ± ±
Magnesium oxide ± 0,5 ± ± ± ± ± ±
Total, phr: 181,0 178,25 178,0 178,0 179,5 178,0 181,0 183,0
Vulcanisation systems systems on compression set has been lows 30 minutes recovery after removal
also studied. Compound formulations of the deformation. The post cure has a
The choice of vulcanisation system de- and their properties are given in Table 1 positive effect on the compression set.
pends on the type of halogenated butyl and Table 2. Compression set data are According to our data, the lowest com-
rubber used. As mentioned earlier, bro- shown in Figures 6 to 9. pression set was obtained with the vulca-
mobutyl and chlorobutyl have quite differ- We have also examined the effect of nisation system based on Zinkoxyd aktiv
ent cure reactivities, bromobutyl showing the test method and post cure on the and zinc diethyl dithiocarbamate (Vulkacit
higher cure versatility and reactivity than compression set. The test procedure of LDA); however, with this curing system
chlorobutyl [5]. We have examined the ef- P-VW 3307 is very severe because of the vulcanisates have the lowest modu-
fect of various curing systems on the phy- the short recovery time of 30 seconds lus.
sical properties of halogenated butyl rub- after removal of the deformation. In com- Based on the results of the work done
bers [6]. The effect of the vulcanisation parison, DBL - 5555 test procedure al- so far, we have found that the optimum
compound for an inner tube is a chloro-
butyl or a bromobutyl compound with a
Table 3. Chlorobutyl Liner Compounds for Air Conditioning Hoses Vulcanisation System vulcanisation system based on zinc oxide
Zinc oxide/HVA#2 and N,N 0 m-phenylenedimaleimide
1289 A 611 612 613 614 (HVA#2). The lowest compression set is
obtained with chlorobutyl-based vulcani-
Chlorobutyl 1240 100 100 100 100
Stearic acid 1,0 1,0 1,0 1,0 sates. The compression set data for this
Carbon black N 772 80,0 80,0 80,0 80,0 curing system for chlorobutyl and bromo-
Zinc oxide 3,0 3,0 3,0 3,0 butyl compounds are shown in Fig-
N,N 0 -Phenylene bismaleimide 1,5 2,0 2,5 3,0
ures 10 and 11. The formulations for
these compounds are given in Tables 3
and 4. These compounds also give the
highest modulus values as required by
Table 3b. Chlorobutyl Liner Compounds for Air Conditioning Hoses Vulcanisation System
Zinc oxide/HVA#2 the VW specification.
Compound 611 612 613 614
Vulcanisate Properties Conclusion
Vulcanisation time at 160 8C (min) 10 10 10 15 The results of our studies show that
Tensile strength (MPa) 14,6 13,7 14,7 13,3 chlorobutyl rubber and bromobutyl
Ultimate elongation (%) 210 175 170 135
Modulus 100 (MPa) 6,4 7,6 8,5 10,0
rubber are excellent base materials
Modulus 200 (MPa) 14,1 ± ± ± for rubber compounds for automotive
air conditioning systems. Vulcanisates
based on these elastomers, when cor-
rectly compounded, meet the most
Table 4. Bromobutyl Liner Compounds for Air Conditioning Hoses Vulcanisation System stringent specification requirements.
Zinc oxide/HVA#2
1289 A 661 662 663 664 665 666
Acknowledgement
Bromobutyl 2030 100,0 100,0 100,0 100,0 100,0 100,0
Stearic acid 1,0 1,0 1,0 1,0 1,0 1,0 The author wishes to thank Bayer AG for permission
Carbon black N 772 80,0 80,0 80,0 70,0 60,0 50,0 to present and publish this paper.
Zinc oxide 3,0 3,0 3,0 3,0 3,0 3,0
N,N 0 Phenylene bismaleimide 1,5 2,0 3,0 2,0 2,0 2,0
Total, phr 185,5 186,0 187,0 176,0 166,0 166,0
Table 4b. Bromobutyl Liner Compounds for Air Conditioning Hoses Vulcanisation System Zinc oxide/HVA#2
1289 A 661 662 663 664 665 666
Vulcanisate Properties
Vulcanisation time at 160 8C 10 min 10 min 15 min 10 min 10 min 10 min
Tensile strength (MPa) 14,7 13,9 14,7 14,6 13,7 13,3
Ultimate elongation (%) 245 205 185 255 265 265
Modulus 100 (MPa) 5,8 6,1 7,5 4,5 4,3 3,9
Modulus 200 (MPa) 13,1 13,9 ±/± 12,0 10,5 10,1
Hardness (Shore A) 72 73 76 67 64 64
Tear strength (ASTMD 624/C) (kN/m) 29,1 26,9 24,1 28,1 27,7 29,4
Tear strength (DIN 53515) (kN/m) 13,8 13,2 11,3 12,3 12,3 11,4
Tear strength (DIN 53507) (kN/m) 2,9 2,9 2,8 3,2 3,8 4,0
Figure 8. Compression set (P-VW 3307) (Bromobutyl Compounds) Figure 9. Compression set (DBL-5555) (Bromobutyl Compounds)
Figure 10. Compression set (P-VW 3307) Figure 11. Compression set (DBL-5555)