Nitrile Rubber
Synthetic Compound Versatility
Discover the versatility of nitrile rubber – a high-performance synthetic rubber known for its exceptional resistance to oils, fuels, and a wide range of chemicals. Learn about its unique properties, manufacturing processes, and diverse applications across various industries, from automotive and aerospace to medical and chemical processing. Nitrile rubber, also known as NBR or Buna-N, is a synthetic rubber copolymer renowned for its exceptional resistance to oils, fuels, and other chemicals. Nitrile rubber was first developed in Germany in the 1930s by chemists at IG Farben. Its initial applications focused on improving the oil resistance of rubber products used in the automotive industry. The characteristics of Buna-N rubber were later commercially available and countries like Great Britain and the United States took notice and eventually set out to develop their own nitrile rubber compounds. During World War II, nitrile rubber played a crucial role in the war effort, particularly in the manufacture of fuel hoses, gaskets, and seals for aircraft and military vehicles. It continued to be a well-used material post-World War II and continues to this day as a foundational material for numerous industrial applications, servicing countless industries.
Nitrile Butadiene
Buna-N/NBR
Producing Nitrile Rubber
Manufacturing nitrile rubber is a process done by the polymerization of acrylonitrile (ACN) and butadiene. Acrylonitrile and butadiene are called monomers and by using a catalyst, a reaction is formed. This process is called polymerization. The result of this process is the copolymer called nitrile rubber. Proportions of acrylonitrile to butadiene can vary to provide the required level of flexibility, strength, and oil resistance to the rubber. These variants are classified by durometer of hardness of the rubber and are generally available from durometer of 35-90. The following table indicates some the better known and used durometers of nitrile rubber:
| Nitrile Rubber Type | Temperature Range | Durometer |
|---|---|---|
| Premium Nitrile | -30°F to +220°F | 40 to 80 |
| Commercial Nitrile | -20°F to +170°F | 40 to 80 |
| FDA Nitrile | -25°F to +180°F | 60 |
| Bio-Diesel Nitrile | -30°F to +220°F | 60 |
| Transformer Nitrile | -30°F to +250°F to -20°F to +250°F | 60 to 70 |
Products manufactured out of nitrile rubber support consumer products to critical industry needs. The chosen manufacturing method depends on the factors such as environment, hardness required, temperature range, function and cost, set forth for each design. Manufacturers working with OEM’s in all fields of discipline will know their best capabilities and recommend the process best suited for any nitrile rubber precision component or product.
Industries Manufacturing With Nitrile Rubber
Nitrile rubber is taken by manufacturers to produce countless products from seals and gaskets to floor mats and footwear. The technologies that are used in to manufacture nitrile rubber-based products also vary and some of the more widely used are:
- Laser Cutting Technology: Lasers do come in different types and characteristics, but those used for laser cutting nitrile rubber are best with the ultraviolet range.
- Die-Cutting: This process is like industrial cookie cutters. Steel dies are used to cut the designed geometry. Good for high volume manufacturing.
- Water Jet Cutting: Pressure streams of water and abrasives cut the materials into the desired profile. No tooling is required.
- Extrusion: This process forces the rubber compound through a shaped die to create continuous lengths of profiles like hoses, tubes, and seals.
- Compression Molding: Rubber compound is placed in a mold cavity and compressed under heat and pressure to form the desired shape.
- Injection Molding: Molten rubber compound is injected into a mold cavity under high pressure, allowing for complex shapes and high production rates.
- Calendering: Rubber compound is passed between heated rollers to produce sheets of varying thickness. These sheets can then be further processed into gaskets, diaphragms, and other components.
- Dipping: This process involves dipping a form or mandrel into a liquid latex solution to create hollow rubber products like gloves and balloons.
Applications Abound
To account for all the products and applications that nitrile rubber is used for would fill volumes of pages. For a glimpse of the applications, you will find nitrile rubber supporting industries and found in products such as:
- Molded Goods
- Oil and Gas
- Hoses and gaskets for refining, transportation
- Pumps, valves, compressors
- Diaphragms for pumps and compressors, O-rings, seals, hoses
- Housing
- Floor mats, seals, adhesives
- Synthetic Leather
- Upholstery, furniture, bags, purses, belts, gloves
- Cable Jacketing
- Automotive
- Fuel systems. hoses,
- Transmission seals, gaskets
- Aircraft Fuel Systems
- Bushings, hoses, gaskets, seals, vibration reduction
- Formulated for FDA Applications
- Catheters
- diaphragms for pumps and valves
- Latex gloves
Manufactured goods from laser cut parts to extruded or molded products, all have in common the characteristics of durability, flexibility, chemical resistance with an extended temperature range of operation made from nitrile rubber. These chemically formed materials offer great benefits when used and have a track record of being reliable and cost effective to both consumers and manufacturers.
Conclusion
There are many applications of nitrile rubber and just a few were mentioned but the list goes on and on. Revered for its high temperature range of operation and chemical resistance, it is advantages for many applications that additionally need good tensile strength, high elongation and are economical when produced. As great as nitrile is, it is not the final solution when it comes to rubber compounds. It has reduced performance under sunlight and when exposed to ozone. It also is not best subjected to flame, ketones and acetates. These conditions are better supported by other materials. As a synthetic material, nitrile rubber stands out as a versatile and high-performance rubber. Its unique properties, combined with its adaptability to various manufacturing processes, make it an invaluable material across numerous industries. From automotive and aerospace to medical and industrial applications, nitrile rubber continues to play a crucial role in enabling innovation and enhancing the performance of countless products and systems.