Standard industrial custom IIR rubber molded parts and extruded components adhere to ASTM D2000 classification standards. Custom formulations are available upon request to meet specialized regulatory or mechanical targets.
|
Property |
Standard Value / Range |
Test Method |
|
Polymer Base |
Isobutylene Isoprene Rubber (IIR) / CIIR / BIIR |
FTIR / DSC |
|
Hardness Range |
40 to 80 Shore A (± 5) |
ASTM D2240 |
|
Tensile Strength |
7 to 18 MPa (Depending on filler loading) |
ASTM D412 |
|
Elongation at Break |
300% to 600% |
ASTM D412 |
|
Compression Set |
<= 25% (22 h at 70°C) |
ASTM D395 Method B |
|
Temperature Range |
-40°C to +120°C (Continuous) |
ASTM D573 |
|
Gas Permeability |
Extremely low (1/10th of natural rubber) |
ASTM D1434 |
|
Standard Thickness |
1.0 mm to 50.0 mm (Sheets); Custom (Molded) |
ISO 3302-1 Class M1 |
The performance profile of IIR rubber is dictated by polymer architecture and compounding ingredients. The backbone features a saturated hydrocarbon chain with minimal unsaturation sites, limiting cross-linking density and restricting molecular mobility—the physical mechanism responsible for its low gas permeability and high butyl rubber gas permeability spec performance.
Polymer Grades:
Utilization of general-purpose IIR, Chlorobutyl (CIIR), and Bromobutyl (BIIR) polymers. Halogenated grades offer superior adhesion to metals and faster curing rates when co-vulcanization with other rubbers is required.
Reinforcing Fillers:
High-structure carbon blacks (e.g., N550, N770) or mineral fillers (calcined clays) are incorporated to optimize tensile strength and tear resistance without degrading elasticity.
Curing Systems:
Resin-cured systems are standard for heat-resistant applications, while sulfur-cured systems are applied for general industrial sealing. Curing kinetics are monitored via moving die rheometer (MDR) testing prior to batch release.
Form Factors:
• Calendered Sheets & Rolls: Uniform thickness with smooth or fabric-impression finishes. Available with or without pressure-sensitive adhesive (PSA) backings.
• Extruded Profiles: Solid cords, hollow tubes, and custom channel sections produced via continuous extrusion and hot-air or salt-bath vulcanization lines.
• Molded Components: Compression, transfer, and injection-molded parts manufactured to tight geometrical tolerances.
Dimensional Tolerances: Molded items conform to ISO 3302-1 (Class M1 for precision parts). Extruded profiles adhere to DIN ISO 3302-1 E2 standards.
Gas & Moisture Barrier:
Demonstrates the lowest gas and vapor transmission rates among general-purpose elastomers, preventing pressure loss in pneumatic and vacuum systems.
01
Chemical Resistance:
Excellent resistance to inorganic acids, alkalis, polar solvents, brake fluids (glycol-based), and animal/vegetable oils. Incompatible with petroleum-based oils, gasoline, and aromatic solvents.
02
Weathering & Ozone:
High resistance to oxygen, ozone, UV radiation, and sunlight degradation without developing surface cracking.
03
Dynamic Damping:
Exhibits high mechanical loss factor (tan delta) across a broad frequency spectrum, making it effective for shock absorption and vibration isolation.
04
Electrical Properties:
High dielectric strength and volume resistivity, suitable for high-voltage insulation applications.
05
Hardness:
Custom formulations adjustable from 40 to 80 Shore A.
Color:
Standard black, grey, white (FDA-compliant formulations available), and custom pigment matching.
Reinforcement Inserts:
Integration of polyester, nylon, or fiberglass fabric plies within elastomer sheets to improve tensile modulus and bolt-load retention in flanged joints.
Surface Treatments:
Chlorination or silicone-free mold-release treatments available to reduce surface friction or prepare parts for secondary bonding.
Production follows strict batch tracking and process control protocols to ensure physical property uniformity.
• Compound Mixing: Raw IIR polymers, fillers, plasticizers, and curing agents are dispersed in an internal intermeshing mixer (Banbury mixer) under controlled thermal parameters to prevent premature scorching.
• Milling & Straining: Mixed compounds pass through a two-roll mill and a strainer-extruderd to remove particulate contaminants and homogenize the compound sheet.
Forming:
Sheets are produced via 4-roll calenders with automated thickness gauge control.
Molded parts are shaped using multi-cavity hydraulic presses equipped with programmable logic controllers (PLCs) regulating temperature, tonnage, and dwell time.
• Vulcanization (Curing): Cross-linking occurs under heat and pressure, fixing the permanent elastic structure.
• Deflashing & Post-Curing: Automated cryogenic deflashing or precision trimming removes flash from molded parts. Post-curing ovens stabilize volatile organic compounds and complete cross-linking reactions.
Fluid & Gas Containment:
Inner liners for pneumatic accumulators, diaphragms for pressure regulators, and vacuum chamber seals.
Automotive & Transportation:
Tire innerliners, radiator hoses, body mounts, and suspension damping buffers.
Electrical Infrastructure:
Cable joint insulation, transformer seals, and high-voltage substation gaskets.
Pharmaceutical & Medical:
Stopper vials, syringe plungers, and fluid transfer tubing requiring low extractables and minimal gas transmission.
Internal quality management systems operate under ISO 9001 standards. Verification is performed at each stage of production.
Raw Material Testing: Mooney viscosity (ASTM D1646) and specific gravity verification on incoming polymer lots.
Rheological Testing: Cure characteristics (scorch time, cure rate index) measured via oscillating disc rheometer for every mixed batch.
Physical Testing: In-house laboratory assessment of tensile strength, elongation, hardness, and compression set on cured test slabs from production lots.
Dimensional Inspection: Optical comparators and digital coordinate measuring machines (CMM) applied to custom molded tooling samples.
Regulatory Compliance: Compounds can be formulated to meet FDA 21 CFR 177.2600 (food contact), USP Class VI, RoHS, and REACH directives.
Engineering support accommodates custom part development from concept to full-scale production as a reliable chlorobutyl rubber sheet supplier and custom compounder.
Tooling Development:
In-house CAD/CAM tool design and CNC machining of steel or aluminum molds for rapid prototyping and production tooling.
Compound Customization:
Formulation adjustments tailored to specific chemical resistance, temperature limits, or regulatory mandates.
Prototyping Services:
Sample runs and 3D-printed master models for fit and function testing prior to production tooling investment.
Rolls & Sheets: Wound on rigid cardboard cores, wrapped in moisture-barrier polyethylene film, and secured on fumigated wooden pallets or in heavy-duty export cartons.
Molded Parts: Packed in anti-static, sealed poly bags within reinforced corrugated master cartons to prevent transit deformation and contamination.
Logistics: Direct sea and air freight capabilities with custom-tailored labeling, barcode tagging, and Certificate of Analysis (CoA) inclusion with every shipment.
Submit your technical drawings, material specifications, and volume requirements to initiate an engineering review and commercial proposal.
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