Back-Up Rings
by Sara McCaslin, PhD Sara McCaslin, PhD No Comments

Choosing the Right Polymer Backup Ring

Choosing the right polymer backup ring can be challenging, but having a basic understanding of how they work, combined with some guidelines, can make the design decisions much easier. This blog post provides a brief overview of what backup rings are, what distinguishes polymer backup rings, and how to choose the right one for a specific application.

Backup Rings

Backup rings are supportive elements typically used with O-rings in sealing systems to help prevent extrusion in the clearance gap of a seal. Often used in high-temperature or high-pressure applications, these rings have lower coefficients of expansion and are engineered to be very rigid and tough. Backup rings can also help to evenly distribute pressure in applications involving varying clearance gaps or pressure fluctuations. Additionally, backup rings help to reduce the effects of wear and friction on O-rings and serve as a thermal barrier to protect them from excessive heat. 

Why Polymer Backup Rings?

Polymer backup rings are often used in place of elastomeric versions because they offer significantly better resistance to extrusion, deformation, chemical resistance, and long-term creep under high pressure. Materials like PTFE, PEEK, or Nylon tolerate wider temperature swings, aggressive fluids, and high-cycle dynamic motion without breaking down. The result is a more stable sealing system with significantly reduced risk of issues such as blowouts, spiral failure, or premature wear. 

Choosing the Right Polymer Backup Ring

There are several different factors that go into selecting the right polymer backup ring. 

Clearance Gap

The clearance gap is one of the most important factors when specifying a polymer backup ring. It directly determines how much support the O-ring needs to prevent extrusion. As the gap increases, the load on the elastomer rises, and the likelihood of extrusion rises sharply. This is especially true at higher pressures or temperatures.

Keep in mind that larger gaps typically require a stiffer polymer (such as PEEK instead of PTFE), a thicker or contoured backup ring profile, or even double backup rings for bidirectional pressure. Small, well-controlled gaps, however, may allow the use of thinner PTFE rings. In short, the wider the clearance gap, the stronger and more dimensionally stable the backup material must be..

Pressure and Temperature

Environmental factors that influence the selection of the right backup ring include system pressure, as higher pressures require harder, more extrusion-resistant materials. System temperatures, which impact dimensional stability, can limit the choice of materials based on their operating temperature limits. High temperatures can make materials more pliable, while low temperatures can lead to brittle behavior. Temperature also affects dimensional stability, as thermal expansion can increase the clearance gap and increase the likelihood of extrusion. 

Static or Dynamic

Another key factor in selecting a backup ring is whether the sealing system will operate in a dynamic or static environment. Static systems will involve less mechanical stress on the backup ring, allowing a wider range of polymer materials to be suitable. In contrast, dynamic applications that introduce continuous motion, friction, and side loading require tougher, more wear-resistant polymers with excellent dimensional stability, such as PEEK or certain PTFE blends. 

Backup Ring Shape

The two most commonly used backup ring shapes are the scarf-cut and solid types. Scarf-cut backup rings feature a single angled split that allows them to flex during installation. They can also conform more easily to the groove and reduce the risk of damage during assembly, since the ring can be expanded or compressed without overstressing the material. Because they can open slightly, scarf-cut rings are often chosen when hardware tolerances are tight or when installation must be done without special tools. 

Solid backup rings do not have a split and must be made from a more flexible polymer that allows them to be stretched or compressed into place without cracking. While they do not offer the same level of extrusion resistance as scarf-cut designs in extreme conditions, their continuous, unbroken profile provides uniform support and is useful in moderate-pressure systems where ease of installation and stable sealing performance are priorities.

Back-Up Ring Material

PTFE is an excellent option for backup rings due to its extremely low coefficient of friction and extensive chemical compatibility. Applications requiring dynamic sealing or very low temperatures are excellent opportunities to use PTFE. PTFE does have its limitations, however. There is the possibility of cold flow under sustained loads, which can make it unsuitable for extreme pressure conditions. Virgin PTFE is limited to about 3,600 psi. Filled PTFE (e.g., glass-filled, carbon-filled, graphite-filled, bronze-filled) is effective for pressures up to 5,800 psi.

PEEK possesses high mechanical strength and excellent resistance to extrusion, with thermal stability up to 480°F and exceptional resistance to extrusion. PEEK can be used at pressures up to 20,000 psi and a maximum temperature of 500°F. These properties make PEEK an excellent option for both high-pressure and high-temperature applications. Additional strength and hardness can be achieved by using various fillers. Finally, PEEK is compatible with a wide range of chemicals and exhibits very low friction. 

Nylon works very well in moderate conditions and is more economical compared to PEEK and PTFE. However, it does have some critical limitations that include swelling and water absorption, both of which can heavily impact tolerances. Nylon 6,6 works well at pressures below 10,000 psi and a maximum temperature of 186°F. Nylon 6,6 filled with Molybdenum Disulfide (MoS2) to reduce friction is commonly used for backup rings. However, one of the drawbacks of Nylon 6,6 is its water absorption, which can range from 0.5% to 1.4% per 24 hours.

Conclusion

Choosing the right polymer backup ring is ultimately about understanding the pressures, temperatures, clearances, and motion your system must withstand. When those variables are matched with the correct geometry and material, you will have a more reliable sealing system with fewer failures and a longer service life. If you need help evaluating your application or choosing the optimal backup ring design, Advanced EMC’s engineering team is ready to assist. Contact us today to discuss your requirements and get expert guidance on the best polymer sealing solution for your equipment.

Spring Energized PTFE Seal
by Sara McCaslin, PhD Sara McCaslin, PhD No Comments

Backup Rings in High-Pressure Sealing Systems: Preventing Seal Extrusion and Extending Service Life

Backup rings in high-pressure sealing systems address face extrusion failure in both dynamic and static seals found in high-pressure systems. Extrusion in sealing occurs when pressurized fluid forces the seal material into the clearance gap between mating surfaces, compromising seal performance. However, backup rings are a simple, low-cost (but critical) solution for extending the service life and maintaining the performance of extreme sealing conditions.

The Challenge of Seal Extrusion in High-Pressure Applications

Seal extrusion happens when pressurized fluid forces part of a sealing element into the clearance gap between mating hardware surfaces. Under high pressure, the soft material deforms plastically and begins to “flow” into this gap, where it can be pinched, torn, or permanently deformed. The result from seal extrusion is nibbling damage along the edges, rapid loss of sealing capability, and, in severe cases, catastrophic leakage.

Extrusion not only shortens seal life but also accelerates equipment wear, drives unplanned downtime, and raises operating costs in hydraulic, pneumatic, and process systems. The causes of seal extrusion are typically high pressure differentials ( > 1500 psi) and/or significant clearance gaps, exacerbated by the use of elastomers or polymers that deform plastically under a load. Seal extrusion can be difficult to avoid under certain circumstances, but that is where backup rings come in.

Backup Rings in High-Pressure Sealing Systems: Purpose and Function

Backup rings in high-pressure sealing systems are annular support components that are installed next to a seal, such as an O-ring or a spring-energized seal. They act as an effective barrier to keep the seal from being forced into the clearance gap.

Backup rings come in different configurations, including single-ring, double-ring (for applications with bi-directional pressure), as well as split vs solid rings. Regardless of the configuration chosen, it is critical to achieve a precise fit because too loose undermines support, while too tight causes problems with assembly.

Material Considerations for Backup Rings in High-Pressure Sealing Systems

The three most commonly used materials for backup rings are PTFE, PEEK, and Nylon. However, other materials such as  UHMW-PE, filled PTFE blends for wear resistance, reinforced polymers for high PV limits, may be used.

PTFE

PTFE is an excellent option for backup rings with its extremely low coefficient of friction and extensive chemical compatibility. It works exceptionally well for applications requiring dynamic sealing or very low temperatures. Its primary limitations are the possibility of cold flow under sustained loads, so it might not always be suitable for extreme pressure conditions.

PEEK

PEEK is another good option for use as a backup ring with its high mechanical strength and excellent resistance to extrusion, as well as its thermal stability up to ~250°C. It also possesses exceptional resistance to extrusion. While it may be a more costly option compared to other polymers, it has found widespread application in industries such as aerospace, oil and gas, and high-performance hydraulics.

Nylon (PA)

Nylon works extremely well in moderate conditions with its strength, and it has a more economical price compared to PEEK and PTFE. However, it does have some critical limitations that including swelling and water absorption, both of which can heavily impact tolerances.

Design and Geometry Options

Solid backup rings provide the best extrusion resistance but can be challenging to install. Split rings can simplify the assembly process, but may allowed extrusion under extremely high loads, which essential defeats the purpose of having a backup ring. Another alternative is the use of spiral cut designs, which balance easier installation (without requiring excessive stretching) with maintaining good support for the seal. Contoured cuts such as scarf of step joints further reduce weak points found at splits.

For pressure direction, a single ring works when the load comes from one side, while double rings are necessary for bidirectional pressure. In every case, the trade-off is clear: easier installation often means slightly higher extrusion risk at the joint.

Engineering Considerations for Integration

Housing tolerances are critical for backup rings. Excessive clearance gaps increase the risk of extrusion, while precise fits provide reliable support. Single rings work well when pressure comes from one direction. However, double rings are required when it fluctuates or is bidirectional. Temperature adds another layer of complexity. Heat accelerates creep and changes dimensions through thermal expansion, which weakens long-term performance. Material compatibility is also important. Chemicals, lubricants, or swelling agents can reduce hardness and shorten service life. In failure analysis, extrusion often appears as edge nibbling or shearing. Compression set, on the other hand, leaves the ring permanently deformed. Recognizing the difference is key to preventing repeat issues.

Conclusion

Backup rings extend seal service life by preventing premature failure and protecting against extrusion. They reduce downtime and maintenance costs, which is especially valuable in high-value systems. Reliability and safety improve in critical applications where failures aren’t an option. They also make it possible to use softer elastomers for better sealing performance without increasing the risk of extrusion.

Investing in the right backup ring extends seal life, reduces failures, and ultimately saves money and downtime. Contact us at Advanced EMC to learn more about backup ring solutions.