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4Butyl Rubbers
Walter H. Waddell and Andy H. Tsou
ExxonMobil Chemical Company, Baytown, Texas, U.S.A.
I. INTRODUCTION
Isobutylene-based elastomers include butyl rubber, halogenated butyl rub-
bers, star-branched versions of these polymers, and the terpolymer bromin-ated isobutylene-co- para-methylstyrene. A number of recent reviews on the
manufacture, physical and chemical properties, and applications of isobutyl-
ene-based elastomers are available (1–7).
Butyl rubber (IIR) is the copolymer of isobutylene and a small amount
of isoprene (see Fig. 1). Patented in 1937 and first commercialized in 1943, the
primary attributes of butyl rubber are excellent impermeability for use as an
air barrier and good flex fatigue properties. These properties result from low
levels of unsaturation in between the long polyisobutylene chain segments.
Tire innertubes were the first major use of butyl rubber, and this continues tobe a significant market today.
The development of halogenated butyl rubbers started in the 1950s.
These polymers greatly extended the usefulness of butyl rubbers by having
faster curing rates and increased polarity. This enabled covulcanization with
general-purpose elastomers such as natural rubber (NR), butadiene rubber
(BR), and styrene butadiene rubber (SBR) that are used in tire compounds.
The enhanced cure properties do not affect the desirable impermeability and
fatigue properties, thus permitting development of more durable tubeless tires
in which the air barrier is an innerliner compound chemically bonded to thecarcass ply. Today, tire innerliners are the largest application for halobutyl
rubber. Both chlorobutyl (CIIR) and bromobutyl (BIIR) rubbers are used
irreversible destruction of the propagating carbenium ion either by the
collapse of the ion pair, by hydrogen abstraction from the comonomer, by
formation of stable allylic carbenium ions, or by reaction with nucleophilicspecies such as alcohols or amines. Termination is imposed after polymeri-
zation to control the molecular weight of the butyl rubber and to provide
inactive polymer for further halogenation.
In the most widely used manufacturing process, a slurry of fine particles
of butyl rubber dispersed in methyl chloride is formed in the reactor after
Lewis acid initiation. The reaction is highly exothermic, and a high molecular
weight can be achieved by controlling the polymerization temperature,
typically between À90jC and À100jC. The most commonly used polymer-
ization process uses methyl chloride as the reaction diluent and boiling liquidethylene 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 initiation and chain transfer reaction rates.
Water and oxygenated organic compounds that can terminate the propaga-
tion step are minimized by purifying the feed systems.
The methyl chloride and unreacted monomers are flashed and stripped
overhead by addition of steam and hot water. They are then dried and purified
in preparation for recycle to the reactor. Slurry aid (zinc or calcium stearate)
and antioxidant are introduced to the hot water–polymer slurry to stabilizethe polymer and prevent agglomeration. The polymer is then screened from
the hot water slurry and dried in a series of extrusion dewatering and drying
steps. Fluid bed conveyors and/or airvey systems are used to cool the hot
polymer crumb to an acceptable packaging temperature. The resultant dried
polymer is in the form of small crumbs, which are subsequently weighed and
compressed into 75 lb bales before being wrapped in EVA film and packaged.
Figure 2 is a schematic of the butyl rubber manufacturing process.
B. Halobutyl Rubbers
Chlorobutyl (CIIR) and bromobutyl (BIIR) rubbers are commercially the
most important derivatives of butyl rubber. The polymerization process for
halobutyl rubber starts with exactly the same processes as for butyl rubber. A
subsequent halogenation step is added. Either reactor effluent polymer, in-
process rubber crumb, or butyl product bales must be dissolved in a suitable
solvent (e.g., hexane or pentane) and all unreacted monomer removed in
preparation for halogenation. Bromine liquid or chlorine vapor is added to
the butyl solution in highly agitated reaction vessels. These ionic halogenationreactions are fast. One mole of hydrobromic or hydrochloric acid is released
for every mole of halogen that reacts; therefore the reaction solution must be
neutralized with caustic such as sodium hydroxide. The solvent is then flashed
and stripped by steam or hot water, with calcium stearate added to prevent
polymer agglomeration. The resultant polymer–water slurry is screened,
dried, cooled, and packaged in a process similar to that of regular (unhalo-genated) butyl rubber.
C. Star-Branched Butyl Rubber
Star-branched butyl rubbers (SBBs) have a bimodal molecular weight
distribution (11) (e.g, see Fig. 3). High molecular weight branched compo-
nents and low molecular weight linear components are both present. Star-
branched butyl rubber is prepared by conventional cationic copolymerization
of isobutylene and isoprene at low temperature in the presence of a polymericbranching agent. The high molecular weight branched molecules are formed
during the polymerization via a graft mechanism. Useful star-branched butyl
rubbers comprise 10–20% high molecular weight components (12). A star
molecule contains 20–40 butyl branches.
Star-branched butyl rubbers have viscoelastic properties that result in
measurably improved processability. Improvements include dispersion of the
polymer during mixing, higher mixing rates, higher extrusion rates, lower die
swell, reduced shrinkage, and improved surface quality. The balance between
green strength and stress relaxation properties at ambient processing temper-atures is also improved (13). Thus, operations such as shaping the innerliner
compound during tire building are easier.
Figure 3 Molecular weight distribution of bromobutyl and star-branched bromo-
Copolymerization of isobutylene with para-methylstyrene produces a satu-
rated copolymer backbone with randomly distributed pendant para-methyl-
styrene substituted aromatic rings. During radical bromination after poly-
merization, some of the substituted para-methylstyrene groups are convertedto reactive bromomethyl groups for vulcanization and functionalization (27).
These saturated terpolymers contain isobutylene, 1–8 mol% para-methyl-
styrene, and 0.5–2.5 mol% brominated para-methylstyrene (see Fig. 7). Their
Figure 6 Schematic drawing of a star-branched butyl rubber chain.
Figure 7 Structure of brominated isobutylene-co- para-methylstyrene (BIMS).
T g values increase with increasing para-methylstyrene content and are around
À58jC. The molecular weight distribution of BIMS is narrow, with M w/
M n< 3.
IV. PHYSICAL PROPERTIES
The physical properties of butyl rubber are listed in Table 1 (1). The physical
properties of polyisobutylene, chlorobutyl rubber, and bromobutyl rubber
are similar. The rotational restriction of the polyisobutylene backbone owing
to the presence of the geminal -dimethyl groups results in a high interchain
interaction and unique William–Landel–Ferry constants compared to hydro-carbon elastomers of similar T g such as natural rubber.
A. Permeability
Primary uses of isobutylene-based elastomers in vulcanized compounds rely
on their properties of low air permeability and high damping. In comparison
with many other common elastomers, isobutylene-based elastomers are
notable for their low permeability to small-molecule diffusants such as He,
H2, O2, N2 and CO2 as a result of their efficient intermolecular packing (28), asevidenced by their relatively high density (0.917 g/cm3). This efficient packing
in isobutylene polymers leads to their low fractional free volumes and low
diffusion coefficients for penetrants. The diffusivities of gases in butyl rubber
and natural rubber are given in Table 2 (29).
Table 1 Physical Properties of Butyl Rubber
Property Value Compositiona
Density, g/cm3 0.917 B
1.130 CBV
Coefficient of volume expansion, 560 Â 10U BV
(1/V )(V /T), K 460 Â 10U CBV
Glass transition temperature, jC À75 to À67 B
1.95 B
Heat capacity, C p, kJ/(kgÁK)b 1.85 BV
0.130 BV
Thermal conductivity, W/(mÁK) 0.230 CBV
Refractive index, n p 1.5081 B
a B = butyl rubber; BV = vulcanized butyl rubber; CBV = vulcanized butyl rubber with 50
As shown in Figure 8, diffusion coefficients of nitrogen in both various
diene rubbers and butyl rubber increase with increasing differences between
the measurement temperature and the corresponding rubber’s glass transition
temperature. However, although the rate of increase in diffusion coefficient
with T ÀT g is about the same for diene rubbers and butyl rubber, the absolute
values of the diffusion coefficient in butyl rubber are significantly less than
those of diene rubbers. Isobutylene copolymers contain only small amounts
of comonomers, and their temperature-dependent permeability values follow
the same curve as for butyl rubber (see Fig. 8). Brominated isobutylene-co-
para-methylstyrene (BIMS) has the highest T g value among isobutylene
copolymers and has the lowest permeability at a given temperature.
B. Dynamic Damping
Polyisobutylene and isobutylene copolymers are high damping at 25jC, withloss tangents covering more than eight decades of frequencies even though
their T g values are less than À60jC (30,31). This broad dispersion in poly-
isobutylene’s dynamic mechanical loss modulus is unique among flexible-
chain polymers and is related to its broad glass–rubber transition (32). The
broadness of the glass–rubber transition, as defined by the steepness index, for
polyisobutylene is 0.65, which is much smaller than that of most polymers. In
addition, polyisobutylene has the most symmetrical and compact monomer
structure among amorphous polymers, which minimizes the intermolecular
interactions and contributes to its unique viscoelastic properties (33,34). As aresult, a separation in time scale between the segmental motion and the Rouse
modes is broader in glass–rubber transition, leading to the appearance of the
sub-Rouse mode (32,35). Considering the differences in temperature depen-
outperformed sidewalls with EPDM blends (52). The bromination and the
para-methylstyrene comonomer levels are important factors for ozone resist-
ance. The BIMS rubber phase must be highly dispersed to minimize crackgrowth (51), and a three-step remill type of mixing sequence is generally
needed to achieve dispersion and co-continuity. Use of a BIMS rubber with a
low bromination level and high para-methylstyrene comonomer content
resulted in property improvements (51,53). Tires having BIMS elastomers
in the black sidewall enhanced tire appearance. A nonstaining black sidewall
formulation is shown in Table 11 (53).
C. Tire White Sidewall and Cover StripChlorobutyl rubber–EPDM rubber–natural rubber blends are used in tire
white sidewall compounds (54) (see Table 12) and in white sidewall cover strip
compounds (55) (see Table 13). The chlorobutyl rubber imparts resistance to
ozone aging, flex fatigue, and staining to the compounds.
D. Tire Treads
The tread is the wear-resistant component of a tire that comes in contact with
the road. It is designed for abrasion resistance, traction, speed, stability, andcasing protection. The tread rubber is compounded for wear, traction, low
rolling resistance, and durability (42). For passenger tires, it is normally
Butyl rubbers are used in blends with BR and NR (see Table 14) to
improve the braking of a winter tire on ice, snow, and/or wet road surfaces; to
lower rolling resistance; and to maintain wear resistance (56). Superior gripand durability are obtained for a CIIR / SBR blend in high-speed tires (57).
Blends of bromobutyl rubber with BR and NR improve lab wear resistance,
the coefficient of friction on ice, and tire operating stability on wet road
surfaces (58). Bromobutyl rubber, star-branched bromobutyl rubber, and
brominated isobutylene-co- para-methylstyrene blends with SBR and BR
increase tangent delta values at low temperatures (À30jC– + 10jC), which
is used as a lab predictor of tire traction properties, and decreases tangent
delta values at higher temperatures (>30jC), which is used as a lab predictorof rolling resistance (59). BIMS/BR/NR winter treads [see Table 15 (60,61)]
sion set to help ensure coupling integrity, and high-temperature stability.
Damping of compressor vibration and noise is also desirable. The hose is
typically a composite of rubber layers and reinforcing yarn. Halobutyl rubberis used in hose covers because of its barrier properties and its resistance to
moisture ingression. Chlorobutyl rubber as a cover for an air-conditioning
hose provides better resistance to moisture ingression than EPDM and is
compatible with operating temperatures up to 120jC (64). Use of a butyl–
halobutyl rubber blend as a layer between the nylon and cover eliminates the
need for an adhesive (see Table 17) (65). A BIMS hose composition exhibits
good physical property retention (66).
A bromobutyl rubber formulation affords better resistance to alterna-
tive fuels such as methanol and an 85:15 methanol–gasoline blend than anitrile compound (see Table 18) (70). It also provides the most resistance and
is impermeable to Delco Supreme II brake fluid (see Tables 19 and 20) (71).
G. Dynamic Parts
Isobutylene-based polymers are used for various types of automotive mounts
because of their ability to damp vibrations from the road or engine, including
body mounts and medium-damping engine mounts. Exhaust hanger straps
use halobutyl rubber because of its heat resistance (see Table 21) (72). A
Table 17 Bromobutyl Compound for Air-Conditioning Hose (phr)
Brominated butyl rubber 100 75
Butyl rubber – 25
N330 carbon black 30 30
N774 carbon black 30 30Precipitated silica, HiSil 233 20 20
Zinc oxide 5 5
Stearic acid 1 1
Antioxidant 1 1
Paraffinic oil, Sunpar 2280 2 2
Brominated alkyl phenol formaldehyde resin 10 10
Hardness, JIS K6262 74 75
Tensile strength, kgÁcm-2 142 151
Elongation at break, % 250 260Permanent set, 25% deflection, 72 hr at 140jC 52.9 51.1
1. Kresge EN, Schatz RH, Wang H-C. Isobutylene polymers. In: Kroschwitz JI, ed.Encyclopedia of Polymer Science and Engineering. Vol. 8. 2d ed. New York:
Wiley, 1987:423.
2. Fusco JV, Hous P. Butyl and halobutyl rubbers. In: Morton M, ed. Rubber
Technology. 3rd ed. New York: Van Nostrand Reinhold, 1987:284.
3. Fusco JV, Hous P. Butyl and halobutyl rubbers. In: Ohm RF, ed. The Vanderbilt