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Technical Elastomers
Technical
Elastomers
Technical Elastomers
Meike Rinnbauer
This book was produced with the technical collaboration of
Freudenberg Sealing Technologies GmbH & Co. KG. Content
Elastomer development 4
Translation: Flanagan Language Services, Aingeal Flanagan, Kln From natural rubber to high-tech material .............................................. 4
Basic principles ....................................................................................... 5
Elastomers and their properties 9
The viscoelastic behavior of elastomers.................................................. 9
The correlation between frequency and temperature .............................. 12
The systematization of elastomers .......................................................... 13
Factors that influence material behavior 16
Compound ingredients ............................................................................ 16
The influence of the cross-link density ................................................... 19
Physical and chemical action .................................................................. 22
Processing techniques 30
Mixing technology .................................................................................. 30
Molding processes................................................................................... 37
Optimizing elastomer processing procedures ......................................... 43
Testing elastomers 46
Testing during the production process..................................................... 46
Estimating the working life ..................................................................... 48
Component simulation using FEM ......................................................... 49
2007 All rights reserved with
High-tech products made of technical elastomers 52
sv corporate media GmbH, D-80992 Munich, Germany
www.sv-corporate-media.de
Outlook 63
First published in Germany in the series
Die Bibliothek der Technik Glossary 66
Original title: Technische Elastomerwerkstoffe
2006 by sv corporate media GmbH Bibliography 67
Illustrations: Freudenberg Sealing Technologies Appendix 68
GmbH & Co. KG, Weinheim
Typesetting: abavo GmbH, D-86807 Buchloe
Printing and binding: Sellier Druck GmbH, D-85354 Freising The company behind this book 71
4 Basic principles 5
Elastomer Fig. 1:
The operating princi-
development
ple of a Simmerring
(cross-section)
featuring an addi-
tional dust lip to
protect the seal
From natural rubber to high-tech against dirt and dust
material
Humankind has been familiar with elastomer
Age-old materials in the form of natural rubbers for
Lubricant
material centuries. Natives in Central and South Amer-
ica used this material for seals and balls. The Dust lip Sealing edge
Grease filling
term caoutchouc comes from the Mayan lan-
guage (cao = tree and ochu = tear) and is a col-
lective term for all non-cross-linked elastic Shaft surface
Discovery of polymers. The accidental discovery of vulcan-
vulcanization ization (curing) by Charles Goodyear in 1839 ogy. The increasing multi-functionality of
paved the way for the manufacture of highly modern elastomeric components means that
flexible cross-linked materials (elastomers), expertise and a wealth of experience are
which in turn made it possible to use these ma- needed for targeted elastomeric development.
terials for countless technical applications. To-
day, elastomers are indispensable for seals and
vibration-control applications. Were it not for
Basic principles
elastomers, there would be no such thing as Polymers are very large molecules that are
cars or planes, and hydraulics and pneumatics formed by the linkage of a large number of
High-tech would be unimaginable. Many of todays elas- very small structural units (monomers). The
products tomer components are high-tech products that monomers are linked by means of functional,
meet even the most exacting requirements re- reactive groups, thereby creating composites
garding temperature, chemical resistance, and that exhibit completely different properties to
wear. A radial shaft seal (Simmerring) is a the starting materials. The molecular structure
perfect example of a highly developed elas- of polymers can be linear, branched, or cross-
tomeric component. It works like a micro- linked. Depending on the orientation of the
scopic pump that transports lubricants or gases molecule chains, a differentiation is made be-
under the sealing edge and back into the oil tween polymers in an amorphous and a par-
chamber, thereby ensuring adequate lubrica- tially crystalline state. The degree of poly- Degree of
tion between the shaft and the seal (Fig. 1). In merization i.e. the number of monomers in polymerization
Additional addition to performing a simple sealing func- a polymer chain has a significant influence
functions tion, seals can also assume other functions on the mechanical properties of the polymers.
when combined with modern sensor technol- As the crystallinity or density of the polymer
6 Elastomer development Basic principles 7
increases, so too do the melting range, tensile Polymer materials are categorized according to
strength, stiffness (elastic modulus), hard- their structure, their mechanical deformation
ness, resistance to solvents, and impermeabil- behavior and, correspondingly, their properties
ity to gases and vapors. and areas of application (Fig. 3). Thermoplas- Thermoplastics
Polymers of high molecular weight such as tics are made up of long and linear or loosely
Viscoelastic elastomers demonstrate a pronounced visco- branched polymers that are not cross-linked.
behavior elastic behavior compared to most other ma- At room temperature they are in a state that is
terials when subjected to mechanical loads. De- somewhere between glassy and ductile. Ther-
pending on the load exerted, the deformation moplastics can have amorphous or partially
that occurs is of an elastic or a viscous nature. crystalline structures. In amorphous thermo-
The key to understanding the mechanical prop- plastics, the polymer chains are arranged in a
erties at various temperatures is a knowledge of random manner both in the molten and in the
the processes that take place in the transition solid state. Partially crystalline thermoplastics
zone between the defined states, which is, are amorphous in the molten state. However,
among other things, characterized by the so- when solid, there are areas in which the poly- Fig. 3:
Glass transition called glass transition temperature or Tg. The mer chains are arranged parallel to one an- Schematic structure
of polymers and
temperature glass transition is a characteristic variable for other. The degree of crystallinity has a signifi- elastic modulus-
every polymer. Below the glass transition tem- cant influence on the mechanical properties of temperature curves
perature, the proper motion of the molecules
which is also known as Brownian motion Thermoplastic Thermoplastic Elastomer Thermoset
freezes. The material is in a hard, glassy state. elastomer
When the glass transition is exceeded, the mol-
ecules become mobile once again and the poly-
mer changes over to a soft, rubbery-elastic state
(Fig. 2). If the temperature continues to rise,
viscous flow occurs followed by decomposi-
tion of the polymer.
Glassy
state
Elastic modulus
Elastic modulus
Elastic modulus
Elastic modulus
Elastic modulus
Elastic
behavior Viscous
flow
Glass
Fig. 2: transition rubbery-elastic
The relationship temperature plateau Temperature Temperature Temperature Temperature
between the elastic Tg
modulus of polymer Temperature = Operative range
and temperature
8 Elastomer development 9
chain segments are merely pushed towards to creep, stress relaxation, or cold flow. Vis-
one another. If stress is applied to the elas- cous flow can be suppressed to a great degree
tomer in this state, the entangled chains are by fixing the chains to one another (cross-
transformed into an arranged and thus less linking). In other words, loose cross-linking
Entropy plausible state (entropy decrease). When the ultimately causes typical rubbery-elastic (elas-
decrease stress is released, the original, more energy- tomeric) behavior. The viscoelasticity of elas-
favorable entangled state is reassumed (en- tomers results in a pronounced time- and tem-
and increase tropy increase). The change in entropy is the perature-dependency for a large number of
driving force behind the resilience of elas- physical and in particular mechanical proper-
tomers in the rubbery-elastic range above the ties. In the case of steel, for example, there is
glass transition temperature Tg (Fig. 4). a linear relationship between stress and strain,
Viscoelastic behavior in elastomers means whereas with elastomer, there is a non-linear
that both the elastic behavior of solids (re- relationship between the two. This non-linear
versible) and the viscous behavior of fluids relationship is demonstrated among other
(irreversible) can be observed. Depending on things by the elastomers dependency on the
the load applied, one or other of the properties deformation speed (Fig. 6).
is more pronounced (Fig. 5). At low tempera- The consequence of this dependency is that
tures and high deformation speeds, the solid elastomers react with great sensitivity to Fig. 6:
Fig. 5:
Spring-damper material behavior dominates, while viscous changes in test conditions. This is why prob- Stress-strain
behavior can be observed at high temperatures lems are frequently encountered in practical diagram
model used to Left-hand diagram:
illustrate elasticity and low deformation speeds. The latter leads operation when correlating simple physical a comparison of
test results with the actual prevailing loads ex- steel, thermoplastic,
State Cause Working model
erted on an elastomer component in the instal- and elastomer
lation space (the complex of loads acting on Right-hand diagram:
the behavior of elas-
Energy Based on reversible changes Spring the component). This means that it is ab- tomers at different
elasticity in the vibration and rotation solutely essential for exact specifications to be deformation speeds
conditions of atoms.
Stress
Stress
center of gravity of the molecule Pseudo-static
(micro-Brownian motion). behavior
and temperature
200 200
In practice, a leap in the mechanical proper-
ties of elastomer are noticeable both at low 100 100
AU
FFKM
PVMQ
FVMQ
VMQ
FKM
AEM
Rubbers
ACM
HNBR
ECO
IIR/CIIR
NBR
EPDM
CR
SBR
NR
Temperature [C]
16 Compound ingredients 17
on the properties of elastomers than inactive quality elastomeric product. This is why car-
fillers, a dependency of mechanical proper- bon blacks that ensure good dispersibility and
ties such as tensile strength, abrasion resis- high processing reliability are now used in
tance, or tear strength on the structure and the production of engineering elastomeric
surface of the carbon blacks and the filler materials.
content can be observed (Fig. 9). A homoge- White fillers such as silicas exhibit similar re- Silicas
Homogeneous neous dispersion (distribution) of fillers in the inforcement potential to carbon blacks. How-
dispersion polymer matrix is the prerequisite for a high- ever, silicas have a marked tendency to ag-
glomerate. They create strong filler networks
28
that are responsible for the reinforcement ef-
fect in the polymer matrix. This is why com-
pounds with active silicas are much more dif-
N 220 ficult to process than compounds with the
21
same amount of carbon black fillers. More-
Tensile strength [MPa]
N 330
over, because of their polarity, silicas disrupt
N 550
the cross-linking with sulfur accelerator sys-
14 tems, which in turn slows down the cross-
N 770 linking process. Consequently, when replac-
ing carbon blacks with silicas, the cross-link-
N 990
7
ing chemistry must be adapted accordingly.
Fig. 9: N 220
The effect of active procedure, chemical bonds are made that
(N 220, N 330), transform the rubber compound into an elas-
semi-active (N 550), 150
and inactive carbon tomer with tailored properties. Curing gener-
blacks (N 770, N 990) ally takes place under pressure and at in-
N 330
on compound 100 creased temperatures (T >140C) in specially
properties such as N 550 constructed tools.
tensile strength and N 770
viscosity is largely 50
N 990 The cross-linking system determines the pro-
determined by the cessing qualities, the chemical structure of
type and proportion the network, and the physical properties of
of the selected 0
the elastomers. This is why the cross-linking
carbon black 0 20 40 60 80 100 120
(phr = parts per Proportion of carbon black [phr] system chosen during the development of the
hundred rubber). elastomer compound plays a decisive role in
20 Factors that influence material behavior The influence of the cross-link density 21
Fig. 11: 1.0 the loss of strength. These changes can take
Cross-linking char- the form of swelling, cracking, embrittle-
acteristics of elas-
tomers determined 0.8 ment, or discoloration of the elastomer. An
by measurement of
Flow
period
Cross-linking
period increase in temperature accelerates the ageing
Torque [Nm]
the torque 0.6 processes considerably. The following rule of
thumb applies: for every 10C increase in
0.4
Cross-link temperature, ageing accelerates by a factor
density
0.2
of between 2 and 4. The life of the component
No is shortened accordingly by the same factor.
cross-link
0
0 1 2 3 4 5 6 Damage caused by oxygen
Time [min]
Seals are exposed to a large number of envi-
ronmental influences such as oxygen, ozone,
time and is used to estimate the cross-link den- UV light, or changing climatic conditions.
sity. The vulcanization curve also sheds light The combination of oxygen in the air and in-
on the viscosity of the compound at curing creased temperatures damages the elastomer Damage to the
temperature. One differentiates between three matrix. This damage can either lead to an ad- elastomer
characteristic periods (Fig. 11): ditional cross-linking of polymer chains or a matrix
Flow period The flow period covers the interval be- degradation of cross-linking points. These in
tween the start of the measurement to the turn lead to a loss of strength, hardening, or
start of cross-linking, i.e. the point at which characteristic cracking, all of which can ulti-
the torque starts to increase. It characterizes mately lead to the failure of the component.
the period of viscous flow, which is used to Diene rubbers such as NR, SBR, and NBR
fill the mold in the tool. During this period, which still contain double bonds in the poly-
the torque initially decreases. mer chain are more sensitive to oxygen and,
Cross-linking The cross-linking period provides informa- most particularly, ozone, than saturated rub-
period tion on the interval between the start of bers such as EPDM, ACM, ECO, etc.
cross-linking to the point when the material In order to retard or to halt the ageing process
is transformed into a dimensionally stable altogether, antioxidants that have been se-
state. lected to suit the elastomer type in question
Cross-linking The cross-link is completed when all possi- are added to elastomer compounds (espe-
completed ble cross-link points have been developed. cially diene rubbers). These antioxidants
The torque stabilizes at this point. chemically neutralize the oxygen in the air so
that oxidation of the polymer chains is reli-
ably prevented. Appropriate anti-ozonants Anti-ozonants
Physical and chemical action and waxes are used to prevent ozone-related and waxes
Depending on the action involved, ageing damage. In the event of permanent deforma-
processes in the elastomer network trigger tion especially in the case of increased tem-
Elastomers age changes that lead to hardening, softening, or peratures chemical processes (chain degra-
24 Factors that influence material behavior Physical and chemical action 25
Fig. 12:
Damage to the 180 3.0
elastomer caused
by exposure to 160 = 0.25 %
2.9
ozone: (a) with anti-
1000/T [K -1]
2.7
elastomer that has
100
not aged
2.6
80
a) b) c)
2.5
60
100 C cont. air
dation, reduction in the number of cross-link 40
110 C cont. air 2.4
120 C cont. air
points, or rearrangements) that lead to a per- 100 C discont. air 2.3
20
manent change in the material can be super- 100 C cont. nitrogen
imposed on the physical processes. Ozone- 0 2.2
related damage to elastomer components is 10-2 10-1 100 101 102 103 104
Time [h]
considerably accelerated if the component in
question is subject to tensile stress. In this
case, characteristic cracks perpendicular to The best protection against ageing for an Fig. 13:
the direction of stress appear. In unfavorable elastomer component depends largely on the Estimated working
life extrapolated
conditions, these cracks can lead to compo- operating conditions for which the compo- from the measured
nent failure (Fig. 12). nent is intended. Only in the most favorable tensile stress relax-
An exact assessment of ageing characteristics of cases will a single antioxidant suffice. As a ation values (mater-
and a more detailed insight into ageing mech- rule, a combination of different antioxidants ial: peroxide-cured
NBR) measured at
Measuring anisms allows chemical stress relaxation to is used. different tempera-
chemical stress be measured at different temperatures. In or- tures in air and
relaxation der to evaluate a variety of chemical influ- The influence of the medium nitrogen
Whenever media such as oils and greases act = elongation
ences better, measurements are also made by EA = activation
comparing them in nitrogen or in fluid media. upon a material, two different processes oc- energy of the ageing
An Arrhenius plot of the results makes it pos- cur: physical swelling and chemical reaction. process
sible to extrapolate the values for long expo- These processes can impair both the elas-
sure times at lower temperatures (Fig. 13). In tomer and its sealing function. The difference
the event of thicker test specimens, the between the two processes is that in the latter,
slower diffusion of oxygen in the elastomer is the influence of the media causes a chemical
the limiting factor for the destruction of the reaction that irreversibly changes the chemi-
elastomer matrix and the associated ageing cal structure of the material.
processes. This explains why in practice, In order to find out whether an elastomeric
thicker elastomer components age much more material is suitable for use in conjunction
slowly than thin elastomer components. with a specific medium, it is stored in the
26 Factors that influence material behavior Physical and chemical action 27
75 NR
50
0 20 40 60 80 100 120 140 160
Swelling in the reference oil IRM 903 [%]
Processing techniques
Proportion model:
Carbon spaghetti
Prerequisites for the production of compo- Polymer black Zinc oxide
nents made of high-performance elastomer tangle aggregate particle (segment)
materials include the reliability of the raw
material quality, exact raw material weight
content, a controlled mixing process, and op-
timized molding processes.
The different raw materials with their varying 190 nm 50 nm Carbon black aggregate N330 1.9 m 0.5 m
320 nm 180 nm Carbon black aggregate N990 3.2 m 1.8 m
Objective: weight contents and consistencies must be 4 nm 2 nm Plasticizer 40 mm 20 mm
creating a processed in such a way as to create a homo- 5 m 5 m Zinc oxide 50 m 50 m
homogeneous geneous compound. Rubber, for example, 0.8 nm 0.8 nm Sulfur/accelerator 8 mm 8 mm
compound is delivered as a plastic polymer in bale or
chip form and decreases in viscosity once it
reaches processing temperature. Plasticizers, celerators). This so-called spaghetti model Fig. 17:
also highlights the demands that are made on Using the so-called
on the other hand, are generally delivered in spaghetti model to
oil form. the mixing process. The art of mixing rubber illustrate the differ-
lies in the breaking up of the various compo- ent sizes of the com-
nents and agglomerates and their even distrib- pound ingredients
The mixing process
ution throughout the polymer matrix in order
The objective of the mixing process is to dis-
to ensure the homogeneous quality of the
tribute all necessary raw materials evenly
compound.
(distributive mixing) and to break up any ag-
As a rule, the various components cannot be Several
glomerates (dispersive mixing) in order to
merged in a single operation. This is particu- operations
achieve an optimum connection between the
larly true of compounds that use fine-particle
filler particles and the polymer. This is partic-
carbon blacks or natural rubber as their poly-
ularly important because the interaction of
mer base. The mixing process is generally di-
the filler particles with the polymer matrix
vided into four stages:
determines several properties, among them
the reinforcement of the elastomer. To illus- The cold raw polymer, which is fed into the
Differently sized trate the different sizes of the compound in- mixing chamber in bale form, must be bro-
compound gredients, figure 17 uses a strand of spaghetti ken up in order to create sufficiently large
ingredients to illustrate the length and diameter of a rub- surfaces for the incorporation of the fillers.
ber molecule and the dimensions of its com- Two contradirectional rotors inside the mix-
ponents (carbon blacks, plasticizers, and ac- ing chamber are used for this purpose.
32 Processing techniques Mixing technology 33
The shear forces generated by the rotors of the thermal processes) and, therefore, the
heat up the polymer, making it less vis- flow characteristics of the materials being
cous. mixed. This is why the timing of the energy
The added fillers and plasticizers must be input is considered to be the finger print of
incorporated so that a coherent mass is cre- the compound (Fig. 18). Continuous docu- Continuous
ated. During this stage, the polymer pene- mentation of the most important process para- documentation
trates the gaps in the filler agglomerates meters such as temperature, speed, time, and
and displaces the air. This part of the pro- energy are therefore used to monitor and en-
Incorporation cess is known as incorporation. sure the quality of the compound. Internal
The fillers, especially the carbon blacks, mixers with intermeshing rotors are preferable
are available in the form of agglomerates for the production of high-quality technical
that are broken up by the shear forces. This elastomer components because they generally
Dispersion part of the process is known as dispersion. ensure a better quality of dispersion and allow
The broken-up fillers are then evenly distri- for faster heat dissipation. This makes low-
buted throughout the polymer matrix. This temperature mixing processes possible.
Distribution part of the process is known as distribution. From the provision of the raw materials to the Fig. 19:
Fig. 18:
delivery of the finished and tested compound, Material flow in
At every stage of the mixing process, changes the production of a batch comprises a large
Time history of the production
process parameters
occur in the surface properties, size, and de-
during the mixing gree of distribution of the additives as well as
process in the flowability of the polymer (as a result White Carbon Bale
fillers black cleaver
Rubber
Oil Oil bale
Temperature Speed
Plunger path Energy
Process parameters
Internal mixer
Material
master data
Molding processes
Feedback
good/bad
(weights)
Batch-off
(weight)
Rubber processing technology is a wide field
that covers numerous processes from the pro-
cessing of fluid latex to extrusion and mold-
ing procedures in self-contained tools and
Record raw materials
Quality assurance
Label/formulation
Manual weighing
widely used molding and curing methods for
assessment
seals and technical molded parts are based on
Batch-off
the production of components in self-con-
Rolling
Mixing
Raw material delivery
Check
Order
tained tools.
Compression molding
Warehouse
Storage
Other technologies
The problem of deflashing or the avoidance
of the formation of flashes in the first place
has led to the development of new processes
Distribution
channels and tools. The surface of the tool can, for ex-
ample, be modified in such a way that air, but
not elastomer, can escape from the mold cav-
ity. This method is known as ready molding,
or the flash-less process, and is particularly
suitable for the manufacture of high-precision
molded parts.
Fig. 23: being introduced into the rubber industry. The The combination of various molding
The principle of structure of the tool used for injection mold-
injection molding
processes has also resulted in the develop-
ing is similar to that used for transfer molding ment of other processes. As the name sug- Injection ready
with the exception that the individual mold gests, the injection ready molding process, for molding
cavities in the latter are connected to the gate example, combines the features of injection
(injection point) by means of channels. The and ready molding. Injection compression Injection
molding process starts when the tool is molding is used to manufacture small, flat compression
closed. The pre-plasticized compound is then molded parts, especially O-rings. This molding
injected at high pressure through the injection process is based on the fact that a very tiny
nozzle into the distribution channels and on gap remains open when the tool is closed.
to the mold cavities (Fig. 23). The preferred The required pre-plasticized compound is
type of injection molding used in the rubber then injected into this gap and the press is
industry features screw pre-plasticization and closed. Flat, high-precision molded parts that
plunger injection. Here, the plasticization and are largely flash-free can be manufactured us-
Separate units injection procedures are kept separate, ing this process.
thereby ensuring that the full potential of For the cold runner injection molding Cold runner in-
every part of the plant can be exploited. As a process, the injection channels are kept ther- jection molding
result of pre-plasticization, the compound is mally separate from the tool. Thanks to the
almost at curing temperature when it enters optimized design of the channel system and
the mold cavity. This means that the actual the fact that the temperature is kept at the
42 Processing techniques Optimizing elastomer processing procedures 43
Fig. 25:
Injection simulation
of a conical spring
illustrates complex
flow processes.
46 Testing during the production process 47
Complex inter- cannot cover all of the complex interrelation- Friction, wear Abrasion
Stress [MPa]
behavior
culated simulation of impact processes. On have long working lives. The loads applied to
the one hand, simulation makes physical inter- the axially symmetrical component are not
relationships more transparent for the user. On themselves axially symmetrical. This is why
the other hand, taking account of non-lineari- a combination of axial and transverse loads
ties in the design process at an early stage al- must be taken into account during the calcu-
Safeguarding lows the functions of the component to be re- lation. The simulation reveals stress peaks in
the component liably secured. Simulations based on FEM the component. These stress peaks can be re-
function models, which describe the behavior of the duced by adapting the design of the compo-
material in exact terms, can make an impor- nent accordingly or, to a certain extent, by
tant contribution in this regard and are gaining optimizing the material. Changes in the com-
in importance. For example, the topology and ponent design have an enormous effect on the
form of components that will be subjected to size of tensile and compressive stresses. In
mechanical loads can be optimized by taking the case of bellows, this means that the maxi-
minor stresses and strains into account. mum stress in the elastomer can be illustrated
and subsequently reduced using simulations, Result:
Fig. 28:
FEM calculation for which in turn means that the working life extended
an axle boot; the red of the component can be extended by up to working life
areas indicate areas 10 percent compared with the conventional
of extreme stress in design (Fig. 28).
the material
control and sealing elements in valves for system channels hot exhaust emissions past
bottling plants. In addition to high media re- the turbocharger during cold starts and full-
sistance, diaphragms must exhibit high abra- load operation. The twin-chamber system
sion resistance and good dynamic properties. comprises two chambers working in the same
The combination of tear strength (e.g. by us- direction that are separated by diaphragms.
ing special fabrics) and flexibility allows di- This system accelerates the light-off perfor-
aphragms to achieve high to extremely high mance of the catalytic converter appreciably.
compressive strength and creep strength. In view of the fact that spark-ignition and
Modern diaphragms that are used in actuators diesel engines have different operating tem-
situated close to the engine translate even the perature ranges, different elastomer com-
tiniest pressure differentials into control and pounds must be used for the diaphragms.
switching operations. Even under critical op- Dynamic seals such as radial shaft seals Dynamic seals
erating conditions e.g. close to turbocharg- (Simmerrings) are used to seal moving parts
ers or in blow-by gas flows that occur in the (e.g. rotating shafts). Among other things,
engine combustion process diaphragms en- they are used to seal crankshafts and
sure long service lives and consistently reli- camshafts in engines or in the drive train of
Example: the able switching precision. One example of passenger cars, commercial vehicles, agricul-
twin-chamber where diaphragms are used in actuators is the tural machinery, and construction machinery,
system twin-chamber system, where they are used as as well as in industrial gears, hydraulic power
a waste gate valve in vehicles (Fig. 31). This units, and washing machines. Dynamic seals
used in industrial applications must last for Service life up
up to 40,000 hours. Despite the use of fric- to 40,000 hours
tion-optimized materials, high shaft speeds
and the resulting high circumferential speeds
often cause extreme temperature increases at
the sealing lip. In adverse conditions, this can
lead to charring of the oil. The build up of
charred oil residue at the sealing edge can ul-
timately result in leakage. This is why the
elastomer used for radial shaft seals must be
capable of withstanding such high tempera-
tures. As a result of the increased use of mod-
ern synthetic lubricants in engines and gears,
elastomers are also exposed to completely
different chemical loads than is the case with
conventional mineral oils. In short, the elas-
Fig. 31: tomers selected for these applications must
Twin-chamber
system acting as a exhibit a high resistance to this new genera-
waste gate valve tion of oil.
58 High-tech products made of technical elastomers High-tech products made of technical elastomers 59
Integral leakage In order to identify functional difficulties in form a sub-assembly. Without the need for
sensor good time, radial shaft seals can also be man- boreholes, seals, and ducts, this multi-func-
ufactured with additional functions such as a tional sealing system allows electrical signals
leakage sensor. to be sent into or out of an area filled with a
If the seals sealing function diminishes once medium and/or subject to pressure. Given the
the product has reached a certain age, a leak- significant design freedom allowed by this
age collector absorbs any fluid that escapes. system, it can be used in a wide range of ap-
An integral sensor identifies the leakage and plications in the automotive and consumer
sends a signal that indicates when the system goods industries as well as for medical and
will need to be serviced and the seal replaced telecommunications technology. The minia-
(Fig. 32). This helps avoid unscheduled ma- turization of this sealing system and the fact Space-saving
chine downtime. that the flexible printed circuit board can be solutions
New ground is also being broken in the fields folded mean that this is a space-saving com-
of control and sensor technology in order to ponent that can be installed in even the small-
meet the requirements of low leakage rates est installation areas.
(in the ppm range), reliability, and cost opti- Bellows and dust boots are both used in the Bellows and
mization. The combination of flexible printed automotive, construction machinery, and food dust boots
circuit board technology and elastomers in industries as well as for electrotechnical ap-
Multi-functional the form of multi-functional sealing systems plications and medical technology. In cars,
sealing systems forms the basis of products that are capable they are used to protect axles, transmission protect sensi-
of simultaneously sealing and transferring in- systems, shock absorbers, and steering sys- tive components
terference-free electric signals without the tems. Drive shafts, propshafts, ball joints in
need for conventional cables (Fig. 33). This tie rods, and stabilizers are all protected
system consists of a static seal with integrated against the infiltration of dirt and moisture by
sensor, a plug, and a flexible printed circuit special elastomeric bellows. Elastomeric bel-
board that connects all the components to lows used in drive shafts also prevent the loss
60 High-tech products made of technical elastomers High-tech products made of technical elastomers 61
of lubricants. Moreover, the bellows must be wipers, U-packings, guide strips, back-up
able to withstand excursions of up to 45 as rings, and rod seals. Sealing elements in the
well as exposure to high temperatures, media, hydraulic cylinders of excavators, wheel
and high local loads. The bellows have a flex- bearings, and earth movers are exposed to
ible center part and two connectors. Appro- particularly high loads. They must be capable
priate connecting elements ensure that the of withstanding both heavy soiling from mud
component sits securely in place and guaran- and dust, as well as major temperature fluctu-
tees the required tightness. The design of the ations. In addition, the sealing system must
bellows depends on the type of joint in ques- not be damaged by high system pressures and
tion and the customers specific requirements. pressure peaks in particular, or by the lateral
As a result of the different loads applied to forces exerted on the hydraulic cylinder. The
fixed and slip joints (inboard and outboard latest generation of hydraulic seals exhibits
mounted), different elastomeric materials are high resilience even at extremely low temper- High resilience
needed to seal them. Joint shaft bellows for atures, thereby allowing mobile hydraulic
fixed joints are preferably made of thermo- systems to perform fully without any note-
plastic elastomers (TPEs), while joint shaft worthy leakages in all climatic zones, even in
bellows for slip joints are generally made of the depths of winter (Fig. 35).
chloroprene rubbers (Fig. 34). Another area of application in which techni- Area of
Sealing systems In view of the increased power density of hy- cal elastomeric materials are used is vibration application:
for hydraulic draulic aggregates, the need for high-perfor- control technology. Vibrations occur in appli- vibration control
aggregates mance, leakage-free components can only be cations where starting torque, imbalances, or technology
met by special sealing systems with long ser- the influence of external forces and torque
vice lives. The sealing systems used in these peaks play a role. The vibrations that are gen-
applications generally comprise a combina- erated in this way not only create noise, they
tion of sealing elements that have been care- also subject components in the drive train to
fully selected to suit each other such as stress, thereby potentially shortening its ser-
Fig. 34:
Elastic protective Fig. 35:
bellows for drive Sealing system for
shafts hydraulic cylinders
62 High-tech products made of technical elastomers 63
stability, which enhance the durability of the about a significant reduction in energy con-
component. sumption and the emission of carbon dioxides
As a result of the growing importance of in the field of transport and energy supply.
electronics in general and the increased use of However, the requirements for seals used in
Integration electric drives, new sealing concepts into fuel cell systems are completely different to Fuel cell
of additional which additional functions are integrated are those for seals used in conventional combus-
functions being developed. These new designs render tion engines. Here, for example, gas perme-
individual components superfluous, thereby ation or very tough requirements regarding
reducing the required installation space, cut- chemical purity play a very important role.
ting weight, and ultimately simplifying instal- Accordingly, the seals used in these systems
lation for the user. For example, radial shaft must be impermeable to gas and exhibit high
seals with elastomeric encoder elements and chemical resistance to the reaction products
active sensors for measuring vehicle speeds, generated in the fuel cell.
especially in ABS systems, are already avail- The trend towards multi-functional sealing
able. These seals feature a magnetizable elas- modules combined with modern processing
tomer layer with encoded sectors (see cover technology makes it possible to produce com-
photo) that is attached either axially or radi- ponents that are both delicate and complex.
ally to the outer side of the seal. A field sen- An in-depth understanding and knowledge of Key to success:
sor registers the varying intensities along the materials and the use of ultra-modern calcula- materials
magnetic field and uses this data to provide a tion processes such as FEM, and high-perfor- expertise
signal that gives information about the speed. mance drawing and construction programs
In future, more consideration must be given such as CAD will further accelerate the de-
to another aspect, namely electromagnetic velopment of innovative elastomeric materi-
shielding. The increase in the number of elec- als that meet the high requirements of quality,
tric systems used in vehicles causes electro- performance, and durability.
magnetic interference, which in turn can
cause components to malfunction. The devel-
Electrically opment of elastomers with increased electri-
conductive cal conductivity prevents electrostatic charge
elastomers and interference caused by the mutual inter-
action of electrical components. Seals made
of such electrically conductive elastomeric
materials will in future be used in the field of
sensor technology or electronic communica-
tions technology.
The development of hydrogen and fuel cell
technology is considered to be an important
pillar of future development. It is fervently
hoped that these technologies will bring
66 Glossary/Bibliography 67
Glossary Rheology The branch of science that deals with the deformation and flow
behavior of materials.
Rubber (Mayan language: cao = tree and ochu = tear) A collective term for
Agglomerates Condensed particles comprising a multitude of individual non-cross-linked, elastic polymers.
particles and measuring between approximately 50 and 100 nanometers (nm)
in diameter. Scorch index The flow period, i.e. the time that elapses prior to cross-link-
ing of the elastomer.
Amorphous The adjective describes materials in which the atoms do not
exhibit an arranged structure, but instead adhere to an irregular pattern. The Simmerring Radial shaft seal, a trademark registered by Freudenberg.
adjective crystalline, on the other hand, is used to describe materials with a Stress relaxation The decrease in stress over time under constant deforma-
regular structure. tion and temperature.
Batch-off plant Situated downstream of the mixing process, this plant is Thermoplastics Plastics that can be plastically deformed under the influence
used to cool the sheeted-out elastomer compound. of heat. Thermoplastics generally comprise polymers with linear or slightly
branched chain molecules.
Brownian motion The phenomenon that describes the thermally driven
proper motion of molecules. Thermosets Plastics that can no longer be molded once they have been
cured.
Creep The temperature- and time-dependent deformation of materials ex-
posed to constant, long-term mechanical load. Torque The product of an applied force and the distance between the point
of application and the fulcrum.
Cross-linking Chemical reaction that is initiated by heat and/or pressure in
which the polymer chains are linked to one another to obtain elastic properties. Viscoelasticity The time-, temperature-, and speed-dependent elasticity of
polymers, molten materials, or solids (plastics).
Curing Process whereby rubber is transformed into a rubbery-elastic state as
a result of a change in its chemical structure; also known as vulcanization.
Diffusion The equalization of differences in concentration between gaseous
or dissolved substances in which particles move dependant on temperature
from the area of higher concentration to the area of lower concentration.
Elastic modulus The tensile modulus of elasticity is an expression of the re-
lationship between tensile stress and elongation. It describes the stiffness of
the elastomer.
Bibliography
Elastomers Polymeric networks that are capable of absorbing large defor- Freudenberg Forschungsdienste KG, Elastomere Werkstoffe (2001).
mations in a reversible manner; cured rubber. Hirsch, V., Schneider, E., and Wei, R., Numerische Berechnungen fr Dich-
Entropy A thermodynamic quantity that describes the molecular mobility tungen und Bauteile, MTZ, Vol. 65, 10/2004, p. 812.
(disorder) of a system. Kaczmarek, M., Rieg, F., Taschenbuch der Maschinenelemente, Hanser und
Flash A protruding edge of elastomer that forms during the molding proce- Fachbuchverlag (Leipzig, 2006).
dure. Krompf, W., Membrantechnik fr motornahe Aktuatoren, MTZ, Vol. 66,
FEM Abbreviation of Finite Element Method; a numerical mathematical 4/2005, p. 288.
method. Mars, W.V., Factors that affect the fatigue life of rubber: a literature survey,
FMEA Abbreviation of Failure Mode and Effects Analysis. The FMEA is an Rubber Chemistry and Technology, Vol. 77, Issue 3, 2004, p. 391.
analytical method of identifying potential weak points. Priebe, N., Kontinuierliches Mischen von Kautschukmischungen, KGK
Glass transition temperature The temperature at which polymers change Kautschuk, Gummi, Kunststoffe, Vol. 58, 03/2005, p. 102108.
from being flexible (the rubbery-elastic state) to being brittle (the energy-elas- Rthemeyer, F. and Sommer, F., Kautschuktechnologie (Hanser Verlag, 2001).
tic state). This temperature varies from one polymer to another. von Arndt, E. and Bumann, M., Gleiche Mischungsqualitt von verschiede-
Polymer A macromolecule made of similar units (monomers). A polymer nen Produktionsstandorten Qualittssystem eines multinationalen Gum-
can be made of linear or branched molecules. miverarbeiters, VDI-Jahrestagung Mischen Extrudieren Spritzgieen (2000).
68 Appendix 69
prene) at T < 0 C construction industries ring resistance Dai-El, precision parts for
Poor low-temperature Noxtite engine applications,
EPDM Ethylene- Very good heat and Dutral, O-rings, molded parts, properties below 20C hydraulics, chemical
propylene- weathering behavior Nordel, bearing elements in the (exception: special types) and process engineering,
diene rubber High ozone resistance Buna EP , food and beverage
aviation
(ethylene- Very good abrasion and
Keltan , industry, also used to
propylene wear resistance Vistalon seal brake fluids in FFKM Perfluoro- Excellent chemical resi- Kalrez, Radial shaft seals,
copolymer) Very good low-temperature automobiles elastomer stance Simriz O-rings, diaphragms,
performance Extreme heat and weathe- molded parts, high-
High hot water and steam ring resistance precision parts for
resistance Special types resistant to chemical and process
Not oil resistant 20C engineering, aerospace
applications, also used
NBR Nitrile Good oil resistance Perbunan, Radial shaft seals, to seal against aggres-
rubber Good damping (as the Nipol, dampers, absorbers, sive media and steam
acrylonitrile content Europrene, diaphragms, hydraulic VMQ Vinyl methyl Extreme heat resistance High-precision parts,
Silopren,
increases) Buna N and pneumatic compo- polysilo- Excellent low-temperature O-rings, flat gaskets,
Silastic,
Good abrasion and wear nents, high-precision xane performance to 60C diaphragms for medical
Elastosil
properties parts, O-rings for drive Low strength applications
Poor ozone resistance and electrical techno-
Moderate ageing resistance logy, in the food indu- FVMQ Fluoro- High heat, ageing, ozone, Silastic, Molded parts, dia-
Moderate low-temperature stry, also used to insu- silicone and weathering resistance FluorSilicon phragms, etc., mainly
properties (depends on late against the cold rubber used in the aviation
the acrylonitrile content) industry
IIR Butyl Excellent heat, ozone, Esso Butyl, Diaphragms, O-rings PVMQ Phenyl- Very good low-temperature GE-Sil, Molded parts, O-rings,
rubber and weathering resistance Polysar for hot water and steam vinyl- resistance, ozone-, UV- Silastic, diaphragms
Chemical resistance to Butyl applications methyl- and weathering-resistant Silopren,
acids, hot water, and polysiloxane Elastosil
glycols AU Polyester Good ageing and ozone Adiprene, Pneumatic and hydraulic
Impermeable to gas urethane resistance Pellethan seals for general mecha-
Good low-temperature rubber High tear strength and nical engineering appli-
resistance wear resistance cations, agricultural and
High damping, heavy de- construction machinery,
pendency on temperature conveyor technology
70 Appendix
Using elastomeric materials in a variety of sealing media The company behind this book
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AU
Freudenberg Sealing Technologies
FKM FFKM VMQ FVMQ GmbH & Co. KG
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+175
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Hhnerweg 24
69465 Weinheim, Germany
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++ Internet: www.FST.com
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+210 +230
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++ very good, + good, (+) satisfactory, 0 moderate, not suitable; special types may deviate from the information provided here
technology solutions for its customers in the automotive, ancillary, and
AEM
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EPDM NBR
ventures around the world and have adapted their company structures to
complement one another. Milestones in the companys globalization in-
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The Simmerring, which was developed at Freudenberg by Prof.
CR
Walther Simmer in 1929, was the starting point for a range that today
includes over 80,000 different sealing technology products. Down
SBR
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NR
HEPG polyglycols
olefins (PAO)
DOT3 /DOT4
Polyalkylene
mately 250 experts in its materials development units around the world.
Poly-alpha-
Engine oils
brake fluid
HFD group
HFB group
HFC group
HFA group
Gear oils
Gasoline
Max. temperature [C]
The company uses more than 1,600 different compounds and more than
Greases
ATF oils
CIP/SIP
Water
degradable HEES
Suds
els developed within the company for calculating and simulating the be-
havior of materials are used to continuously enhance and refine
lubricants
lubricants
Synthetic
hydraulic
hydraulic
hydraulic
resistant
Mineral
Flame-
media
fluids
fluids
fluids
Other
Bio-