U.S. patent application number 10/189332 was filed with the patent office on 2003-10-30 for novel elastomer composites, method and apparatus.
Invention is credited to Andrews, Malcolm John, Chung, Bin, Mabry, Melinda Ann, Morgan, Allan Clark, Podobnik, Ivan Zlatko, Rumpf, Frederick Harry, Shell, James A., Tokita, Noboru, Wang, Ting, Westveer, Scott Adrian.
Application Number | 20030203992 10/189332 |
Document ID | / |
Family ID | 24504864 |
Filed Date | 2003-10-30 |
United States Patent
Application |
20030203992 |
Kind Code |
A1 |
Mabry, Melinda Ann ; et
al. |
October 30, 2003 |
Novel elastomer composites, method and apparatus
Abstract
Elastomer composites are produced by novel continuous flow
methods and apparatus in which fluid streams of particulate filler
and elastomer latex are fed to the mixing zone of a coagulum
reactor to form a mixture in semi-confined flow continuously from
the mixing zone through a coagulum zone to a discharge end of the
reactor. The particulate filler fluid is fed under high pressure to
the mixing zone, such as to form a jet stream to entrain elastomer
latex fluid sufficiently energetically to substantially completely
coagulate the elastomer with the particulate filler prior to the
discharge end. Highly efficient and effective elastomer coagulation
is achieved without the need for a coagulation step involving
exposure to acid or salt solution or the like. Novel elastomer
composites are produced. Such novel elastomer composites may be
cured or uncured, and combine material properties, such as choice
of filler, elastomer, level of filler loading, and
macro-dispersion, not previously achieved.
Inventors: |
Mabry, Melinda Ann;
(Cleveland Heights, OH) ; Rumpf, Frederick Harry;
(Billerica, MA) ; Podobnik, Ivan Zlatko; (Nashua,
NH) ; Westveer, Scott Adrian; (Westford, MA) ;
Morgan, Allan Clark; (Manchester, MA) ; Chung,
Bin; (Nashua, NH) ; Andrews, Malcolm John;
(Bryan, TX) ; Wang, Ting; (Billerica, MA) ;
Shell, James A.; (Suwanee, GA) ; Tokita, Noboru;
(Woodbridge, CT) |
Correspondence
Address: |
BANNER & WITCOFF
28 STATE STREET
28TH FLOOR
BOSTON
MA
02109-1775
US
|
Family ID: |
24504864 |
Appl. No.: |
10/189332 |
Filed: |
July 2, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10189332 |
Jul 2, 2002 |
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09407773 |
Sep 28, 1999 |
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6413478 |
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09407773 |
Sep 28, 1999 |
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08823411 |
Mar 25, 1997 |
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6048923 |
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08823411 |
Mar 25, 1997 |
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08625163 |
Apr 1, 1996 |
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Current U.S.
Class: |
523/335 ;
524/495 |
Current CPC
Class: |
C08C 1/15 20130101; B29B
7/7495 20130101; C08K 3/36 20130101; B29K 2021/00 20130101; C08K
3/04 20130101; B29B 15/04 20130101; C08J 3/215 20130101; B01F 25/23
20220101; B29B 7/76 20130101; B29K 2105/16 20130101; C08J 2321/00
20130101; C08J 3/205 20130101; C08K 3/04 20130101; C08L 21/00
20130101; C08K 3/36 20130101; C08L 21/00 20130101 |
Class at
Publication: |
523/335 ;
524/495 |
International
Class: |
C08K 003/00; C08K
003/04 |
Claims
We claim:
1. A method of producing elastomer composite, comprising: feeding a
continuous flow of first fluid comprising elastomer latex to a
mixing zone of a coagulum reactor defining an elongate coagulum
zone extending from the mixing zone to a discharge end; feeding a
continuous flow of second fluid comprising particulate filler under
pressure to the mixing zone of the coagulum reactor to form a
mixture with the elastomer latex, the mixture passing as a
continuous flow to the discharge end and the particulate filler
being effective to coagulate the elastomer latex, wherein mixing of
the first fluid and the second fluid within the mixing zone is
sufficiently energetic to substantially completely coagulate the
elastomer latex with the particulate filler prior to the discharge
end; and discharging a substantially continuous flow of elastomer
composite from the discharge end of the coagulum reactor.
2. The method of producing elastomer composite in accordance with
claim 1 wherein the second fluid is fed to the mixing zone through
a nozzle at a velocity of 100 to 800 feet per second.
3. The method of producing elastomer composite in accordance with
claim 2 wherein the first fluid is fed continuously into the mixing
zone at a velocity lower than 12 feet per second.
4. The method of producing elastomer composite in accordance with
claim 1 wherein the elastomer latex is natural rubber latex and the
particulate filler is carbon black.
5. The method of producing elastomer composite in accordance with
claim 1 further comprising feeding an auxiliary fluid to the mixing
zone, the auxiliary fluid being substantially non-reactive with the
mixture.
6. The method of producing elastomer composite in accordance with
claim 5 wherein the auxiliary fluid is air.
7. The method of producing elastomer composite in accordance with
claim 1 wherein the coagulum zone has progressively increasing
cross-sectional area in the direction from the mixing zone to the
discharge end.
8. A continuous flow method of preparing elastomer composite of
particulate filler dispersed in elastomer, comprising: A)
establishing a continuous, semi-confined flow of mixed elastomer
latex and particulate filler under pressure in a coagulum reactor
forming an elongate coagulum zone extending with progressively
increasing cross-sectional area from an entry end to a discharge
end, by simultaneously (i) feeding elastomer latex fluid
continuously to a mixing zone at the entry end of the coagulum
reactor, and (ii) entraining the elastomer latex fluid into
particulate filler fluid by feeding the particulate filler fluid as
a continuous jet into the mixing zone, and B) discharging from the
discharge end of the coagulum reactor a substantially constant flow
of elastomer composite globules concurrently with feeding of the
fluid streams in accordance with steps A(i) and A(ii).
9. The continuous flow method of producing elastomer composite in
accordance with claim 8 wherein coagulation of the elastomer latex
is substantially complete in the elastomer composite globules as
they are discharged from the discharge end of the coagulum
reactor.
10. The continuous flow method of producing elastomer composite in
accordance with claim 8 further comprising the step of preparing
the particulate filler fluid by high energy dispersion of the
particulate filler in a liquid in a homogenizer having an outlet
port in fluid communication with the mixing zone.
11. The continuous flow method of producing elastomer composite in
accordance with claim 8 wherein the liquid slurry is fed into the
mixing zone through a nozzle at a velocity of 100 to 800 feet per
second.
12. The continuous flow method of producing elastomer composite in
accordance with claim 11 wherein the velocity of the liquid slurry
through the nozzle is from 200 to 500 feet per second.
13. The continuous flow method of producing elastomer composite in
accordance with claim 8 further comprising the step of premixing
minor amounts of additives into the elastomer latex prior to
feeding the elastomer latex to the mixing zone.
14. The continuous flow method of producing elastomer composite in
accordance with claim 8 wherein the particulate filler fluid is an
aqueous carbon black dispersion.
15. The continuous flow method of producing elastomer composite in
accordance with claim 8 wherein the particulate filler fluid
comprises silicon treated carbon black, fumed silica, precipitated
silica, and mixtures of any of them.
16. The continuous flow method of preparing elastomer composite in
accordance with claim 8 wherein the elastomer latex fluid consists
essentially of natural rubber latex.
17. The continuous flow method of preparing elastomer composite in
accordance with claim 16 wherein the natural rubber latex is
natural rubber latex concentrate.
18. The continuous flow method of preparing elastomer composite in
accordance with claim 16 wherein the natural rubber latex is field
latex.
19. The continuous flow method of producing elastomer composite in
accordance with claim 8 further comprising mixing additive into the
semi-confined flow by separately feeding an additive fluid
continuously to the mixing zone simultaneously with the elastomer
latex fluid and the particulate filler fluid.
20. The continuous flow method of producing elastomer composite in
accordance with claim 8 wherein the additive is selected from
antiozonants, antioxidants, plasticizers, processing aids, resins,
flame retardants, extender oils, lubricants, and mixtures of any of
them.
21. The continuous flow method of producing elastomer composite in
accordance with claim 8 further comprising injecting pressurized
gas into the mixing zone.
22. The continuous flow method of producing elastomer composite in
accordance with claim 21 wherein the pressurized gas is injected
separately into the mixing zone.
23. The continuous flow method of producing elastomer composite in
accordance with claim 21 wherein the pressurized gas is injected
into the mixing zone through a nozzle together with the particulate
filler fluid.
24. The continuous flow method of producing elastomer composite in
accordance with claim 8 wherein step A(ii) comprises feeding
multiple streams of particulate filler fluid to the mixing zone
continuously through multiple nozzles.
25. The continuous flow method of producing elastomer composite in
accordance with claim 8 further comprising, simultaneously with
steps A(i) and A(ii), feeding at least one auxiliary stream of
elastomer latex fluid to the mixing zone.
26. The continuous flow method of producing elastomer composite in
accordance with claim 8 further comprising the step of drying the
elastomer composite globules received from the discharge end of the
coagulum reactor, through a dryer.
27. The continuous flow method of producing elastomer composite in
accordance with claim 26 further comprising the step of baling the
elastomer composite by sequentially compressing 25 to 75 pound
quantities of the elastomer composite after the drying step.
28. The continuous flow method of producing elastomer composite in
accordance with claim 8 wherein the elastomer latex fluid is fed
under pressure less than 10 psig and the particulate filler fluid
is fed under pressure of at least 75 psig.
29. A continuous flow method of producing rubber master batch by
coagulating natural rubber latex with carbon black, comprising: A)
establishing a continuous, semi-confined flow of mixed natural
rubber latex and carbon black in a coagulum reactor forming a
generally tubular coagulum zone extending with progressively
increasing cross-sectional area from an entry end to an open
discharge end, by simultaneously (i) feeding a liquid stream of the
natural rubber latex continuously to a mixing zone at the entry end
of the coagulum reactor, and (ii) entraining the natural rubber
latex continuously into a liquid slurry of the carbon black by
feeding the liquid slurry as a continuous jet into the mixing zone;
and B) simultaneously discharging rubber master batch globules from
the discharge end of the coagulum reactor.
30. A continuous flow method of producing elastomer composite
comprising particulate filler selected from carbon black,
silicon-treated carbon black, fumed silica, precipitated silica,
and mixtures thereof finely dispersed in natural rubber,
comprising. preparing a particulate filler fluid by high energy
dispersion of the particulate filler into aqueous liquid in a
homogenizer; and establishing a continuous, semi-confined flow of
mixed natural rubber latex and particulate filler in a coagulum
reactor forming a generally tubular coagulum zone extending with
progressively increasing cross-sectional area from an entry end to
a discharge end by simultaneously (i) feeding a liquid stream of
the natural rubber latex at less than 10 feet per second
continuously to a mixing zone defined by a mix head in sealed fluid
communication with the entry end of the coagulum reactor, the
mixing zone extending coaxially with the coagulum zone, and (ii)
entraining the natural rubber latex continuously into the
particulate filler fluid by projecting the particulate filler fluid
into the mixing zone in the direction of the entry end of the
coagulum zone, through a feed tube substantially coaxial with the
coagulum zone, the particulate filler fluid exiting the feed tube
at a velocity of 200 to 500 feet per second; simultaneously and
continuously discharging from the discharge end of the coagulum
reactor master batch globules in which coagulation of the natural
rubber latex by the particulate filler is substantially complete;
and simultaneously and continuously drying and pelletizing master
batch globules discharged from the coagulum reactor in at least one
dryer.
31. Apparatus for producing elastomer composite of particulate
filler dispersed in elastomer, comprising: a coagulum reactor
defining a mixing zone and an elongate coagulum zone extending from
the mixing zone to a discharge end; latex feed means for feeding
elastomer latex fluid continuously to the mixing zone; and filler
feed means for feeding particulate filler fluid as a continuous jet
into the mixing one to form a mixture with the elastomer latex
fluid traveling from the mixing zone to the discharge end of the
coagulum zone, wherein the distance between the mixing zone and the
discharge end is sufficient to permit substantially complete
coagulation of the elastomer latex prior to the discharge end.
32. The apparatus for producing elastomer composite in accordance
with claim 31 wherein the filler feed means is for feeding
particulate filler fluid continuously to the mixing zone through a
nozzle at a velocity of 100 to 600 feet per second.
33. The apparatus for producing elastomer composite in accordance
with claim 32 wherein the latex feed means is for feeding elastomer
latex fluid continuously into the mixing zone at a velocity less
than 8 feet per second.
34. The apparatus for producing elastomer composite in accordance
with claim 31 wherein the filler feed means is for feeding
particulate filler fluid continuously to the mixing zone under
pressure of at least 75 pounds per square inch (gauge).
35. The apparatus for producing elastomer composite in accordance
with claim 34 wherein the latex feed means is for feeding elastomer
latex fluid continuously into the mixing zone under pressure less
than 12 pounds per square inch.
36. The apparatus for producing elastomer composite in accordance
with claim 31 further comprising auxiliary feed means for
simultaneously feeding an additional stream of pressurized fluid to
the mixing zone.
37. The apparatus for producing elastomer composite in accordance
with claim 36 wherein the pressurized fluid is air.
38. The apparatus for producing elastomer composite in accordance
with claim 31 wherein the coagulum zone has progressively
increasing cross-sectional area between the mixing zone and the
discharge end.
39. Apparatus for continuous flow production of elastomer composite
of particulate filler dispersed in elastomer, comprising: a
coagulum reactor forming an elongate coagulum zone extending with
progressively increasing cross-sectional area from an entry end
toward a discharge end; means for feeding elastomer latex fluid
continuously to a mixing zone at the entry end of the coagulum
reactor; and means for feeding particulate filler fluid
sufficiently energetically into the mixing zone to create
semi-confined flow of mixed elastomer latex and particulate filler
in the coagulum zone toward the discharge end and achieve
substantial coagulation of the elastomer latex with the particulate
filler prior to the discharge end.
40. Apparatus for producing elastomer composite of particulate
filler dispersed in elastomer, comprising: a coagulum reactor
forming an elongate coagulum zone extending with progressively
increasing cross-sectional area from an entry end to a discharge
end; means for feeding elastomer latex fluid continuously to a
mixing zone at the entry end of the coagulum reactor; and means for
feeding to the mixing zone a continuous jet of particulate filler
fluid, under pressure, effective to entrain elastomer latex fluid
into a mixture with the particulate filler fluid and to
substantially completely coagulate the elastomer latex with the
particulate filler prior to the mixture arriving at the discharge
end.
41. The apparatus for continuous flow production of elastomer
composite in accordance with claim 40 wherein the mixing zone is
within a mix head and is substantially coaxial with the elongate
coagulum zone.
42. The apparatus for continuous flow production of elastomer
composite in accordance with claim 41 wherein the mix head is
sealed to a coagulum zone extender.
43. The apparatus for continuous flow production of elastomer
composite in accordance with claim 42 wherein the means for feeding
a stream of particulate filler fluid comprises a first feed tube
extending substantially coaxially within the mixing zone to a
slurry nozzle tip open toward the coagulum zone.
44. The apparatus for continuous flow production of elastomer
composite in accordance with claim 43 wherein: the mix head forms a
first feed channel substantially coaxial with the coagulum zone,
extending from an entry port toward the coagulum zone; and the
first feed tube extending coaxially within the first feed channel
forms a fluid tight seal with the mix head at the entry port.
45. The apparatus for continuous flow production of elastomer
composite in accordance with claim 44 wherein the first feed tube
extends from the entry port to a slurry nozzle tip and wherein a
constant diameter land within the first feed tube immediately
upstream of the slurry nozzle tip has an axial dimension at least
three times its diameter.
46. The apparatus for continuous flow production of elastomer
composite in accordance with claim 44 wherein the means for feeding
elastomer latex fluid comprises a second feed channel formed by the
mix head at an angle of 30.degree. to 90.degree. to the first feed
channel, enwinding to a junction with the mixing zone from a second
entry port remote from the mixing zone.
47. The apparatus for continuous flow production of elastomer
composite in accordance with claim 45 wherein the cross-sectional
area of the coagulum zone immediately downstream of the mixing zone
is more than twice the cross-sectional diameter of the first feed
tube.
48. The apparatus for continuous flow production of elastomer
composite in accordance with claim 47 wherein the cross-sectional
area of the coagulum zone immediately downstream of the mixing zone
is about 4 to 8 times the cross-sectional area of the first feed
tube.
49. The apparatus for continuous flow production of elastomer
composite in accordance with claim 45 wherein the mix head forms at
least one additional feed channel at an angle of 30.degree. to
90.degree. to the first feed channel, extending to a junction with
the mixing zone from an entry port remote from the mixing zone.
50. The apparatus for continuous flow production of elastomer
composite in accordance with claim 40 wherein at least a first
portion of the coagulum zone extending from the entry end toward
the discharge end has a circular cross-section and a central
longitudinal axis, the circular cross-section increasing in size at
an overall angle greater than zero degrees and less than 25 degrees
to the central longitudinal axis.
51. The apparatus for continuous flow production of elastomer
composite in accordance with claim 40 wherein the cross-sectional
area of the coagulum zone increases continuously toward the
discharge end.
52. The apparatus for continuous flow production of elastomer
composite in accordance with claim 50 wherein the cross-sectional
area of the coagulum zone increases step-wise from the entry end
toward the discharge end.
53. The apparatus for continuous flow production of elastomer
composite in accordance with claim 51 wherein said first portion of
the coagulum zone comprises: a first section of substantially
constant diameter D.sub.1 extending a length L.sub.1 from the entry
end toward the discharge end, L.sub.1 being at least three times
D.sub.1, and multiple additional sections each having substantially
constant cross-sectional diameter, at least twice the
cross-sectional area of an immediately preceding section, and a
length equal to at least three times its cross-sectional
diameter.
54. The apparatus for continuous flow production of elastomer
composite in accordance with claim 53 wherein the length L.sub.1 of
the first section is about 12 to 18 times its diameter D.sub.1.
55. The apparatus for continuous flow production of elastomer
composite in accordance with claim 54 wherein the coagulum zone
extending from the entry end toward the discharge end has circular
cross-section, increases in size step-wise toward the discharge
end, and has: a first section beginning at the entry end having a
substantially constant cross-sectional diameter D.sub.1 equal to 5
to 8 times the cross-sectional diameter of the nozzle, a
cross-sectional area A.sub.1, and a length L.sub.1 which is 12 to
18 times D.sub.1; a second section extending toward the discharge
end from a faired connection to the first section, having a
substantially constant cross-sectional diameter D.sub.2, a
cross-sectional area A.sub.2 approximately two times A.sub.1, and a
length L.sub.2 approximately three to seven times D.sub.2; a third
section extending toward the discharge end from a faired connection
to the second section, having a substantially constant
cross-sectional diameter D.sub.3, a cross-sectional area A.sub.3
approximately two times A.sub.2, and a length L.sub.3 approximately
three to seven times D.sub.3; and a fourth section extending toward
the discharge end from a faired connection to the third section,
having a substantially constant cross-sectional diameter D.sub.4, a
cross-sectional area A.sub.4 approximately two times A.sub.3, and a
length L.sub.4 approximately three to seven times D.sub.4.
56. The apparatus for continuous flow production of elastomer
composite in accordance with claim 40 further comprising a diverter
for receiving elastomer composite from the discharge end of the
coagulum zone and passing the elastomer composite selectively to
any of multiple receiving sites.
57. The apparatus for continuous flow production of elastomer
composite in accordance with claim 56 wherein the diverter
comprises a flexible conduit having a first end attached to the
discharge end of the coagulum reactor and a second end moveable to
any of the multiple receiving sites.
58. The apparatus for continuous flow production of elastomer
composite in accordance with claim 56 wherein the means for feeding
particulate filler fluid comprises pumping means for developing
said pressure to greater than 75 psig and the means for feeding
elastomer latex fluid comprises a holding tank and feed line for
developing less than 10 psig elastomer latex fluid pressure.
59. The apparatus for continuous flow production of elastomer
composite in accordance with claim 40, wherein the particulate
filler fluid is carbon black slurry comprising carbon black in a
carrier liquid, further comprising carbon black slurry preparation
means in fluid communication with the means for feeding particulate
filler fluid to the mixing zone, comprising: a mixing tank for
agitated mixture of carbon black and carrier liquid, having a
discharge port for discharging a mixture fluid; a colloid mill for
dispersing carbon black in the carrier liquid to form a dispersion
fluid, having an intake port in fluid communication with the
discharge port of the mixing tank and an outlet port for
discharging the dispersion fluid; and an homogenizer for more
finely dispersing the carbon black in the carrier liquid to form
the carbon black slurry, having an inlet port in fluid
communication with the discharge port of the colloid mill and an
exit port for passing carbon black slurry to the means for feeding
particulate filter fluid to the mixing zone.
60. An elastomer composite comprising elastomer in which
particulate filler has been dispersed by: feeding a continuous flow
of first fluid comprising elastomer latex to a mixing zone of a
coagulum reactor defining an elongate coagulum zone extending from
the mixing zone to a discharge end; feeding a continuous flow of
second fluid comprising particulate filler under pressure to the
mixing zone of the coagulum reactor to form a mixture with the
elastomer latex, the mixture passing as a continuous flow to the
discharge end, and the particulate filler being effective to
coagulate the elastomer latex, wherein mixing of the first fluid
and the second fluid within the mixing zone is sufficiently
energetic to substantially completely coagulate the elastomer latex
with the particulate filler prior to the discharge end; and
discharging a substantially continuous flow of elastomer composite
from the discharge end of the coagulum reactor.
61. An elastomer composite comprising particulate filler finely
dispersed in elastomer, formed by a continuous flow method
comprising the steps of: A) establishing a continuous,
semi-confined flow of mixed elastomer latex and particulate filler
under pressure in a coagulum reactor forming an elongate coagulum
zone extending with progressively increasing cross-sectional area
from an entry end to a discharge end, by simultaneously (i) feeding
elastomer latex fluid continuously to a mixing zone at the entry
end of the coagulum reactor, and (ii) entraining the elastomer
latex fluid into particulate filler fluid by feeding the
particulate filler fluid as a continuous jet into the mixing zone;
and B) discharging from the discharge end of the coagulum reactor a
substantially constant flow of elastomer master batch globules
concurrently with feeding of the fluid streams in accordance with
steps A(i) and A(ii).
62. An elastomer composite formed by a continuous flow method
comprising the steps of:. A) establishing a continuous
semi-confined flow of mixed natural rubber latex and carbon black
in a coagulum reactor forming a generally tubular coagulum zone
extending with progressively increasing cross-sectional area from
an entry end to an open discharge end, by simultaneously (i)
feeding a liquid stream of the natural rubber latex continuously to
a mixing zone at the entry end of the coagulum reactor, and (ii)
entraining the natural rubber latex continuously into a liquid
slurry of the carbon black by feeding the liquid slurry as a
continuous jet into the mixing zone; and B) simultaneously
discharging elastomer composite globules from the discharge end of
the coagulum reactor.
63. An elastomer composite formed by a continuous flow method
comprising the following steps: preparing a particulate filler
fluid by high energy dispersion of the particulate filler into
aqueous liquid in a homogenizer; and establishing a continuous,
semi-confined flow of mixed natural rubber latex and particulate
filler in a coagulum reactor forming a mixing zone and a generally
tubular coagulum zone extending with progressively increasing
cross-sectional area from the mixing zone to a discharge end by
simultaneously (i) feeding a liquid stream of the natural rubber
latex at less than 10 feet per second continuously to a mixing zone
defined by a mix head in sealed fluid communication with a coagulum
zone extender, the mixing zone extending coaxially with the
coagulum zone, and (ii) entraining the natural rubber latex
continuously into the particulate filler fluid by feeding the
particulate filler fluid into the mixing zone through a feed tube
substantially coaxial with the coagulum zone, the particulate
filler fluid exiting the feed tube at a velocity of 200 to 500 feet
per second; simultaneously and continuously discharging from the
discharge end of the coagulum reactor globules of the elastomer
composite in which coagulation of the natural rubber latex by the
particulate filler is substantially complete; and simultaneously
and continuously drying and pelletizing globules discharged from
the coagulum reactor.
64. An elastomer composite comprising particulate filler dispersed
in elastomer, the macro-dispersion D (%) of the particulate filler
in the elastomer composite being less than 0.2% undispersed
area.
65. The elastomer composite of claim 64 wherein the particulate
filler is carbon black, silicon coated carbon black, silicon
treated carbon black, fumed silica, precipitated silica or a
mixture of any of them.
66. The elastomer composite of claim 64 wherein the elastomer is
natural rubber, a chlorinated derivative of natural rubber, or a
homopolymer, copolymer or terpolymer of butadiene, styrene,
isoprene, isobutylene, 3,3-dialkyl-1, 3-butadiene where the alkyl
group is C1 to C3 alkyl, acrylonitrile, ethylene or propylene.
67. An elastomer composite comprising at least 30 phr particulate
filler dispersed in elastomer, the particulate filler being
selected from carbon black, silicon coated carbon black, silicon
treated carbon black, fumed silica, precipitated silica or a
mixture of any of them and the elastomer being selected from
natural rubber, or a homopolymer, copolymer or terpolymer of
butadiene, styrene, isoprene, isobutylene, 3,3-dialkyl-1,
3-butadiene where the alkyl group is C1 to C3 alkyl, acrylonitrile,
ethylene or propylene, wherein macro-dispersion D (%) of the
particulate filler in the elastomer composite being less than 0.2%
undispersed area.
68. The elastomer composite of claim 67 further comprising at least
one additive selected from antizonants, antioxidants, plasticizers,
processing aids, resins, flame retardants, extender oils,
lubricants, and mixtures of any of them.
69. The elastomer composite of claim 67 wherein the
macro-dispersion D (%) is less than 0.1% undispersed area.
70. An elastomer composite comprising natural rubber and 30 to 75
phr carbon black having structure and surface area ratio DBPA: CTAB
less than 1.2, having macro-dispersion D (%) no greater than
0.3%.
71. The elastomer composite of claim 70 wherein the carbon black
has structure and surface area ratio DBPA: CTAB less than 1.0.
72. An elastomer composite comprising carbon black dispersed in
natural rubber, the macro-dispersion D (%) of the carbon black in
the elastomer composite being less than 0.2% undispersed area.
73. The elastomer composite of claim 72 wherein the
macro-dispersion D (%) of the carbon black in elastomer composite,
measured as percent undispersed area for defects larger than 10
microns, is less than 0.1%.
74. The elastomer composite of claim 72 wherein the elastomer
composite is unvulcanized and the MW.sub.sol (weight average) of
the elastomer composite is at least 0.45.times.10.sup.6.
75. The elastomer composite of claim 72 wherein the carbon black
has surface area CTAB greater than 45.
76. The elastomer composite of claim 72 wherein the elastomer
composite comprises at least 30 phr carbon black.
77. The elastomer composite of claim 72 further comprising from 0
to 20 phr extender oil.
78. An elastomer composite comprising carbon black dispersed in
natural rubber, the carbon black having structure and surface area
properties of Region I of FIG. 8, wherein the elastomer composite
has MW.sub.sol and macro-dispersion D (%) in the area below line
101 in FIG. 10.
79. An elastomer composite comprising carbon black dispersed in
natural rubber, the carbon black having structure and surface area
properties of Region II of FIG. 8, wherein the elastomer composite
has MW.sub.sol and macro-dispersion D (%) in the area below line
111 in FIG. 11.
80. An elastomer composite comprising carbon black dispersed in
natural rubber, the carbon black having structure and surface area
properties of Region III of FIG. 8, wherein the elastomer composite
has MW.sub.sol and macro dispersion D (%) in the area below line
121 in FIG. 12.
81. An elastomer composite comprising natural rubber, 30 to 75 phr
carbon black having surface area of CTAB from 45 to less than 250
and 0 to 20 phr extender oil, the elastomer composite having
macro-dispersion D (%) of the carbon black in the natural rubber,
as follows: D(%).ltoreq.0.2% (i) when
MW.sub.sol.ltoreq.0.45.times.10.sup.6; and log (D).ltoreq.log
(0.2)+2.0.times.(MW.sub.sol-0.45.times.10.sup.6).times.10.sup.-6
(ii) when
0.45.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6.
82. An elastomer composite comprising natural rubber, 30 to 75 phr
carbon black having surface area of CTAB of 45 to 250 and structure
of DBPA (cc/100 g) less than 110 where CTAB is greater than 65 and
less than 250, and DBPA less than 80+1.6 (CTAB-45) where CTAB is
from 45 to less than 65, and 0 to 20 phr extender oil, the
elastomer composite having macro-dispersion D (%) of the carbon
black in the natural rubber, as follows: D(%)<1.0% (i) when
MW.sub.sol is less than 0.7.times.10.sup.6; and log (D)<log
1.0+2.5.times.(MW.sub.sol-0.7.time- s.10.sup.6).times.10.sup.4 (ii)
when 0.7.times.10.sup.6<MW.sub.sol<-
;1.1.times.10.sup.6.
83. An elastomer composite comprising natural rubber, 30 to 70 phr
carbon black having structure DBPA from 110 to less than 80+1.6
(CTAB-45), and surface area of CTAB greater than 65 and less than
250, and 0 to 20 phr extender oil, the elastomer composite having
macro-dispersion D (%) of the carbon black in the natural rubber,
as follows: D<0.3% (i) when MW.sub.sol is less than
0.35.times.10.sup.6; and log
(D)<log.times.(0.3)+2.8(MW.sub.sol-0.35.times.10.sup.6).times.10.sup.6
(ii) when
0.35.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6.
84. An elastomer composite comprising natural rubber and 40 to 70
phr carbon black having structure DBPA (cc/100 g) from 80+1.6
(CTAB-45) to 160, and surface area CTAB from 45 to less than 90,
and 0 to 20 phr extender oil, the elastomer composite having
macro-dispersion D (%) of the carbon black in the natural rubber as
follows: D(%)<0.1% (i) when MW.sub.sol is less than
0.35.times.10.sup.6; and log (D)<log
(0.1)+2.0.times.(MW.sub.sol-0.30.times.10.sup.6).times.10.sup.-6
(ii) when
0.3.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6.
85. An elastomer composite comprising natural rubber, 30 to 70 phr
STERLING.RTM. 6740 carbon black, and 0 to 20 phr extender oil, the
elastomer composite having macro-dispersion D (%) of the carbon
black in the natural rubber, as follows: D(%)<0.1% (i) when
MW.sub.sol is less than 0.3.times.10.sup.6; and log (D)<log
(0.1)+2.0.times.(MW.sub.- sol-0.3.times.10.sup.6).times.10.sup.-6
(ii) when
0.3.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6.
86. An elastomer composite comprising natural rubber, 30 to 70 phr
N234 carbon black, and 0 to 20 phr extender oil, the elastomer
composite having macro-dispersion D (%) of the carbon black in the
natural rubber, as follows: D(%)<0.3% (i) when MW.sub.sol is
less than 0.35.times.10.sup.6; and log
(D)<log.times.(0.3)+2.8(MW.sub.sol-0.35.t-
imes.10.sup.6).times.10.sup.6 (ii) when
0.35.times.10.sup.6<MW.sub.so- l<1.1.times.10.sup.6.
87. An elastomer composite comprising natural rubber, 30 to 70 phr
N110 carbon black, and 0 to 20 phr extender oil, the elastomer
composite having macro-dispersion D (%) of the carbon black in the
natural rubber as follows: D(%)<0.5% (i) when MW.sub.sol is less
than 0.35.times.10.sup.6; and log (D)<log
(0.5)+2.5.times.(MW.sub.sol-0.35.- times.10.sup.6).times.10.sup.-6
(ii) when 0.35.times.10.sup.6<MW.sub.-
sol<1.1.times.10.sup.6.
88. An elastomer composite comprising natural rubber, 30 to 70 phr
N326 carbon black, and 0 to 20 phr extender oil, the elastomer
composite having macro-dispersion D (%) of the carbon black in the
natural rubber as follows: D(%)<1.0% (i) when MW.sub.sol (weight
average) is less than 0.7.times.10.sup.6; and log (D)<log
(1.0)+2.5.times.(MW.sub.sol-0- .7.times.10.sup.6).times.10.sup.-6
(ii) when 0.7.times.10.sup.6<MW.su-
b.sol<1.1.times.10.sup.6.
89. An elastomer composite comprising natural rubber, 30 to 70 phr
BLACK PEARL.RTM. 800 carbon black, and 0 to 20 phr extender oil,
the elastomer composite having macro-dispersion D (%) of the carbon
black in the natural as follows: D(%)<1.5% (i) when MW.sub.sol
is less than 0.65.times.10.sup.6; and log (D)<log
(1.5)+2.5.times.(MW.sub.sol-0.65.- times.10.sup.6).times.10.sup.6
(ii) when 0.65.times.10.sup.6<MW.sub.s-
ol<1.1.times.10.sup.6.
90. An elastomer composite comprising natural rubber, 30 to 70 phr
REGAL.RTM. 660 carbon black, and 0 to 20 phr extender oil, the
elastomer composite having macro-dispersion D (%) of the carbon
black in the natural rubber as follows: D(%)<1.0% (i) when
MW.sub.sol is less than 0.6.times.10.sup.6; and log (D)<log
(1.0)+2.5.times.(MW.sub.sol-0- .6.times.10.sup.6).times.10.sup.-6
(ii) when 0.6.times.10.sup.6<MW.su-
b.sol<1.1.times.10.sup.6.
91. An elastomer composite comprising natural rubber, 30 to 70 phr
REGAL.RTM. 250 carbon black, and 0 to 20 phr extender oil, the
elastomer composite having macro-dispersion D (%) of the carbon
black in the natural rubber as follows: D(%)<1.0% (i) when
MW.sub.sol is less than 0.6.times.10.sup.6; and log (D)<log
(1.0)+2.5.times.(MW.sub.sol-0- .6.times.10.sup.6).times.10.sup.-6
(ii) when 0.6.times.10.sup.6<MW.su-
b.sol<1.1.times.10.sup.6.
92. An elastomer composite comprising natural rubber, 30 to 70 phr
N330 carbon black, and 0 to 20 phr extender oil, the elastomer
composite having macro-dispersion D (%) of the carbon black in the
natural rubber as follows: D(%)<1.0% (i) when MW.sub.sol is less
than 0.6.times.10.sup.6; and log (D)<log
(1.0)+2.5.times.(MW.sub.sol-0.6.ti- mes.10.sup.6).times.10.sup.6
(ii) when 0.6.times.10.sup.6<MW.sub.sol&-
lt;1.1.times.10.sup.6.
93. An elastomer composite comprising natural rubber, 30 to 70 phr
N351 carbon black, and 0 to 20 phr extender oil, the elastomer
composite having macro-dispersion D (%) of the carbon black in the
natural rubber as follows: D (%)<0.3% (i) when MW.sub.sol is
less than 0.55.times.10.sup.6; and log (D)<log
(0.3)+2.0.times.(MW.sub.sol-0.55.- times.10.sup.6).times.10.sup.6
(ii) when 0.55.times.10.sup.6<MW.sub.s-
ol<1.1.times.10.sup.6.
94. An elastomer composite comprising natural rubber, 30 to 70 phr
particulate filler comprising a blend of carbon black and silica,
and 0 to 20 phr extender oil, the elastomer composite having
macro-dispersion D (%) of the particulate filler in the natural
rubber as follows: D(%)<0.8% (i) when MW.sub.sol is less than
0.5.times.10.sup.6; and log (D)<log
(0.8)+2.2.times.(MW.sub.sol-0.5.times.10.sup.6).times.10.s- up.-6
(ii) when
0.5.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6.
95. The elastomer composite of claim 94 wherein the particulate
filler comprises at least about 60% carbon black.
96. An elastomer composite comprising natural rubber, 30 to 70 phr
silicon-treated carbon black, and 0 to 20 phr extender oil, the
elastomer composite having macro-dispersion D (%) of the
silicon-treated carbon black in the natural rubber as follows:
D(%)<1.0% (i) when MW.sub.sol is less than 0.4.times.10.sup.6;
and log (D)<log
(1.0)+2.0.times.(MW.sub.sol-0.4.times.10.sup.6).times.10.sup.6 (ii)
when 0.4.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6.
97. A vulcanizate comprising carbon black dispersed in natural
rubber, the macro-dispersion D (%) of the carbon black in the
elastomer composite being less than 0.2%.
98. A vulcanizate of claim 97 wherein the macro-dispersion D (%) of
the carbon black in the elastomer composite is less than 0.1%.
99. Cured elastomer composite in accordance with any of claims 60
to 98.
100. Tire tread comprising cured elastomer composite in accordance
with claim 99.
101. Tire sub-tread comprising cured elastomer composite in
accordance with claim 99.
102. Wire-skim for a tire comprising elastomer composite in
accordance with claim 99.
103. Tire sidewall comprising elastomer composite in accordance
with claim 99.
104. Cushion gum for a re-tread tire, comprising elastomer
composite in accordance with claim 99.
105. A rubber component of an engine mount, comprising elastomer
composite in accordance with claim 99.
106. Tank track comprising elastomer composite in accordance with
claim 99.
107. Mining belt, comprising elastomer composite in accordance with
claim 99.
108. A rubber component of a hydro-mount comprising elastomer
composite in accordance with claim 99.
109. A Edge bearing comprising elastomer composite in accordance
with claim 99.
110. A seismic isolator comprising elastomer composite in
accordance with claim 99.
111. Cured elastomer composite in accordance with any of claims 60
to 98 having a crack growth rate measured in accordance with ASTM
D3629-94 no more than 1.20 cm/million cycles.
112. A vulcanizate having a crack growth rate measured in
accordance with ASTM D3629-94 of no more than about 1.20 cm/million
cycles.
113. A method of producing elastomer composite, comprising: feeding
a flow of first fluid comprising elastomer latex to a mixing zone
of a coagulum reactor defining an elongate coagulum zone extending
from the mixing zone to a discharge end; feeding a flow of second
fluid comprising particulate filler under pressure to the mixing
zone of the coagulum reactor to form a mixture with the elastomer
latex, the mixture passing as a continuous flow to the discharge
end and the particulate filler being effective to roagulate the
elastomer latex, wherein mixing of the first fluid and the second
fluid within the mixing zone is sufficiently energetic to
substantially completely coagulate the elastomer latex with the
particulate filler prior to the discharge end; and discharging a
flow of elastomer composite from the discharge end of the coagulum
reactor.
Description
FIELD OF THE INVENTION
[0001] The present invention is directed to novel methods and
apparatus for producing elastomer composites, and to novel
elastomer composites produced using such methods and apparatus.
More particularly, the invention is directed to continuous flow
methods and apparatus for producing elastomer masterbatch of
particulate filler finely dispersed in elastomer, for example,
elastomer composites of carbon black particulate filler finely
dispersed in natural rubber, such as curative-free masterbatch
compositions, curative-bearing base compositions, and rubber
materials and products formed of such masterbatch compositions.
BACKGROUND
[0002] Numerous products of commercial significance are formed of
elastomeric compositions wherein particulate filler is dispersed in
any of various synthetic elastomers, natural rubber or elastomer
blends. Carbon black, for example, is widely used as a reinforcing
agent in natural rubber and other elastomers. It is common to
produce a masterbatch, that is, a premixture of filler, elastomer
and various optional additives, such as extender oil. Carbon black
masterbatch is prepared with different grades of commercially
available carbon black which vary both in surface area per unit
weight and in "structure." Numerous products of commercial
significance are formed of such elastomeric compositions of carbon
black particulate filler dispersed in natural rubber Such products
include, for example, vehicle tires wherein different elastomeric
compositions may be used for the tread portion, sidewalls, wire
skim and carcass. Other products include, for example, engine mount
bushings, conveyor belts, windshield wipers and the like. While a
wide range of performance characteristics can be achieved employing
currently available materials and manufacturing techniques, there
has been a long standing need in the industry to develop
elastomeric compositions having improved properties and to reduce
the cost and complexity of current manufacturing techniques. In
particular, it is known for example that macro-dispersion level,
that is, the uniformity of dispersion of the carbon black or other
filler within the elastomer, can significantly impact performance
characteristics. For elastomeric compositions prepared by
intensively mixing the carbon black or other filler with natural
rubber or other elastomer (such as in a Banbury mixer or the like),
any increase in macro-dispersion requires longer or more intensive
mixing, with the consequent disadvantages of increased energy
costs, manufacturing time, and similar concerns. For carbon black
fillers of certain surface area and structure characteristics,
dispersion beyond a certain degree has not been possible or
commercially practicable using known mixing apparatus and
techniques. In addition, such prolonged or more intensive mixing
degrades the natural rubber by reducing its molecular weight,
rendering the finished elastomeric compound undesirable for certain
applications.
[0003] It is well known to employ carbon blacks having higher or
lower structure and surface area to manipulate the performance
characteristics of an elastomeric composition. Carbon blacks of
higher surface area and lower structure are known to improve crack
growth resistance and cut-and-chip resistance as well as,
generally, abrasion resistance, and other performance qualities.
Commercially available mixing techniques have been unable to
achieve excellent uniformity of dispersion of carbon blacks
throughout the elastomer, however, without unacceptable degradation
of the natural rubber. In fact, for typical carbon black loading
levels in natural rubber, such as 45 phr to 75 phr, and oil loading
from 0 phr to 10 phr, low structure carbon backs, such as carbon
blacks of DBPA less than 110 cc/100 g, particularly those having
surface above about 45 m.sup.2/g to 65 m.sup.2/g (CTAB), it has not
been possible to achieve compounds having less than about 1%
undispersed carbon black (measured as macro-dispersion, as
described below) regardless of the duration and level. Furthermore,
as noted above, in the highly energy consumptive intensive dry
mixing methods currently in widespread commercial use, the
mastication of the elastomer necessary for dispersing such carbon
blacks results in unacceptable levels of disruption of the
polymeric chains of the natural rubber elastomer. The resultant
reduction in the molecular weight of the natural rubber is
undesirable for many industrial applications. For use in tire
tread, for example, reduced molecular weight is known to cause an
undesirable increase in the so-called rolling resistance of the
tire.
[0004] Furthermore, while theoretical analysis has indicated
desirable improvements in certain performance characteristics of
elastomeric compositions employing carbon blacks of higher surface
area and lower structure, it has not been possible using known
physical milling or other mastication processes to obtain such
elastomeric compositions in which both the molecular weight of the
natural rubber is well preserved and satisfactory macro-dispersion
levels of the carbon black are achieved. Generally, it has been
found, for example, that the elastomer reinforcing properties of a
carbon black increase as the particle size of the carbon black
decreases. However, with extremely fine carbon blacks an anomalous
condition is known to be encountered, in which the expected
improvement in properties is not achieved. This is understood to be
due at least in part to the inability of conventional elastomer
compounding methods to adequately disperse the carbon black in the
natural rubber without undue breakdown of the elastomer polymer.
There has been, therefore, consequent inability to take full
advantage of the natural affinity of the carbon black and the
natural rubber for each other in the case of such carbon
blacks.
[0005] Since good dispersion of carbon black in natural rubber
compounds has been recognized for some time as one of the most
important objectives for achieving good quality and consistent
product performance, considerable effort has been devoted to the
development of procedures for assessing dispersion quality in
rubber. Methods developed include, e.g. the Cabot Dispersion Chart
and various image analysis procedures. Dispersion quality can be
defined as the state of mixing achieved. An ideal dispersion of
carbon black is the state in which the carbon black agglomerates
(or pellets) are broken down into aggregates (accomplished by
dispersive mixing) uniformly separated from each other
(accomplished by distributive mixing), with the surfaces of all the
carbon black aggregates completely wetted by the rubber matrix
(usually referred to as incorporation).
[0006] Common problems in the rubber industry which are often
related to poor macro-dispersion can be classified into four major
categories: product performance, surface defects, surface
appearance and dispersion efficiency. The functional performance
and durability of a carbon black-containing rubber formulation,
such as tensile strength, fatigue life and wear resistance, are
affected substantially by macro-dispersion quality. Undispersed
carbon black can also cause surface defects on finished products,
including visible defects. Eliminating the presence of surface
defects is of critical importance in molded thin parts for
functional reasons and in extruded profiles for both aesthetic and
functional reasons.
[0007] A commercial image analyzer such as the IBAS Compact model
image analyzer available from Kontron Electronik GmbH (Munich,
Germany) can be used to measure macro-dispersion of carbon black or
other filler. Typically, in quantitative macro-dispersion tests
used in the rubber industry, the critical cut-off size is 10
microns. Defects larger than about 10 microns in size typically
consist of undispersed black or other filler, as well as any grit
or other contaminants, which can affect both visual and functional
performance. Thus, measuring macro-dispersion involves measuring
defects on a surface (generated by microtoming, extrusion or
cutting) greater than 10 microns in size by total area of such
defects per unit area examined using an image analysis procedure.
Macro-dispersion D (%) is calculated as follows: 1 % Undispersed
area ( % ) = 1 A m i = 1 m N i D i 2 4
[0008] where
[0009] A.sub.m=Total sample surface area examined
[0010] N.sub.i=Number of defects with size D.sub.i
[0011] D.sub.i=Diameter of circle having the same area as that of
the defect (equivalent circle diameter).
[0012] m=number of images
[0013] Macro-dispersion of carbon black or other filler in uncured
natural rubber or other suitable elastomer can be assessed using
image analysis of cut surface samples. Typically, five to ten
arbitrarily selected optical images are taken of the cut surface
for image analysis. Knife marks and the like preferably are removed
using a numerical filtering technique. Cut surface image analysis
thus provides information regarding the carbon black dispersion
quality inside a natural rubber compound. Specifically, percent
undispersed area D(%) indicates carbon black macro-dispersion
quality. As macro-dispersion quality is degraded, percent
undispersed area increases. Dispersion quality can be improved,
therefore, by reducing the percent undispersed area. As noted
above, the mixing operations have a direct impact on mixing
efficiency and on macro-dispersion. In general better carbon black
macro-dispersion is achieved in the elastomer, for example in a
natural rubber masterbatch, by longer mixing and by more intensive
mixing. Unfortunately, however, achieving better macro-dispersion
by longer, more intensive mixing, degrades the elastomer into which
the carbon black is being dispersed. This is especially problematic
in the case of natural rubber, which is highly susceptible to
mechanical/thermal degradation. Longer and more intensive mixing,
using known mixing techniques and apparatus, such as a Banbury
mixer, reduces the molecular weight of the natural rubber
masterbatch-composition. Thus, improved macro-dispersion of carbon
black in natural rubber is known to be achieved with a
corresponding, generally undesirable reduction in the molecular
weight of the rubber.
[0014] In addition to dry mixing techniques, it is known to
continuously feed latex and a carbon black slurry to an agitated
coagulation tank. Such "wet" techniques are used commonly with
synthetic elastomer, such as SBR. The coagulation tank contains a
coagulant such as salt or an aqueous or acid solution typically
having a pH of about 2.5 to 4. The latex and carbon black slurry
are mixed and coagulated in the coagulation tank into small beads
(typically a few millimeters in diameter) referred to as wet crumb.
The crumb and acid effluent are separated, typically by means of a
vibrating shaker screen or the like. The crumb is then dumped into
a second agitated tank where it is washed to achieve a neutral or
near neutral pH. Thereafter the crumb is subjected to additional
vibrating screen and drying steps and the like, Variations on this
method have been suggested for the coagulation of natural and
synthetic elastomers. In U.S. Pat. No. 4,029,633 to Hagopian et al,
which like the present invention is assigned to Cabot Corporation,
a continuous process for the preparation of elastomer masterbatch
is described. An aqueous slurry of carbon black is prepared and
mixed with a natural or synthetic elastomer latex. This mixture
undergoes a so-called creaming operation, optionally using any of
various known creaming agents. Following the creaming of the carbon
black/latex mixture, it is subjected to a coagulation step.
Specifically, the creamed carbon black/latex mixture is introduced
as a single coherent stream into the core of a stream of
coagulating liquor. The solid stream of creamed carbon black/latex
mixture is said to undergo shearing and atomizing by the stream of
coagulating liquor prior to coagulation, being then passed to a
suitable reaction zone for completion of the coagulation. Following
such coagulation step, the remainder of the process is
substantially conventional, involving separation of the crumb from
the waste product "serum" and washing and drying of the crumb. A
somewhat similar process is described in U.S. Pat. No. 3,048,559 to
Heller et al. An aqueous slurry of carbon black is continuously
blended with a stream of natural or synthetic elastomer or latex.
The two streams are mixed under conditions described as involving
violent hydraulic turbulence and impact. As in the case of the
Hagopian et al patent mentioned above, the combined stream of
carbon black slurry and elastomer latex is subsequently coagulated
by the addition of an acid or salt coagulant solution.
[0015] There has long been a need in various industries for
elastomeric compounds of particulate filler dispersed in suitable
elastomer, especially, for example, carbon black dispersed in
natural rubber, having improved macro-dispersion. As discussed
above, improved macro-dispersion can provide correspondingly
improved aesthetic and functional characteristics. Especially
desirable are new elastomeric compounds of carbon black in natural
rubber wherein improved macro-dispersion is achieved together with
higher molecular weight of the natural rubber. It is an object of
the present invention to meet some or all of these long felt
needs.
SUMMARY OF THE INVENTION
[0016] In accordance with a first aspect, a method for preparing
elastomer masterbatch involves feeding simultaneously a particulate
filler fluid and an elastomer latex fluid to a mixing zone of a
coagulum reactor. A coagulum zone extends from the mixing zone,
preferably progressively increasing in cross-sectional area in the
downstream direction from an entry end to a discharge end. The
elastomer latex may be either natural or synthetic and the
particulate filler fluid comprises carbon black or other
particulate filler effective to coagulate the latex. The
particulate filler fluid is fed to the mixing zone preferably as a
continuous, high velocity jet of injected fluid, while the latex
fluid is fed at low velocity. The velocity, flow rate and
particulate concentration of the particulate filler fluid are
sufficient to cause mixture with high shear of the latex fluid and
flow turbulence of the mixture within at least an upstream portion
of the coagulum zone so as to substantially completely coagulate
the elastomer latex with the particulate filler prior to the
discharge end. Substantially complete coagulation can thus be
achieved, in accordance with preferred embodiments, without the
need of employing an acid or salt coagulation agent.
[0017] In accordance with another aspect, a continuous flow method
of producing elastomer masterbatch comprises the continuous and
simultaneous feeding of latex fluid and particulate filler fluid to
the mixing zone of the coagulum reactor establishing a continuous,
semi-confined flow of a mixture of the elastomer latex and
particulate filler in the coagulum zone. Elastomer masterbatch
crumb in the form of "worms" or globules are discharged from the
discharge end of the coagulum reactor as a substantially constant
flow concurrenty with the on-going feeding of the latex and
particulate filler fluid streams into the mixing zone of the
coagulum reactor. Notably, the plug-type flow and atmospheric or
near atmospheric pressure conditions at the discharge end of the
coagulum reactor are highly advantageous in facilitating control
and collection of the elastomer masterbatch product, such as for
immediate or subsequent further processing steps.
[0018] In accordance with an apparatus aspect, means are provided
for feeding elastomer latex fluid to the mixing zone of the
aforesaid coagulum reactor, preferably under low pressure,
substantially laminar type flow conditions, and means are provided
for simultaneously feeding particulate filler fluid to the mixing
zone under pressure sufficient to create a jet of sufficient
velocity or kinetic energy to entrain the elastomer latex as
described above, and achieve coagulation before the mixture flowing
downstream from the mixing zone reaches the discharge end of the
coagulum reactor. In accordance with certain preferred embodiments
described in detail below, means for feeding the elastomer latex
fluid and separate means for feeding the particulate filler fluid
each may comprise a feed channel in a mix head integral with a
substantially tubular member defining the coagulum zone. The mixing
zone may be provided at the junction of such feed channels within
the mix head. In accordance with certain preferred embodiments, the
mixing zone is simply a coaxial extension of the coagulum zone.
Progressive increase in the cross-sectional area of the coagulum
reactor is continuous in certain preferred embodiments and is
step-wise in other preferred embodiments. Additionally, the
coagulum reactor may be provided with such optional features as a
diverter at its discharge end, as further described below.
Additional optional and preferred features of the apparatus
disclosed here for continuous flow production of elastomer
masterbatch are discussed in the detailed description below.
[0019] In accordance with yet another aspect, elastomer composites
are provided as a product of the process or apparatus disclosed
above. In accordance with preferred embodiments, novel elastomer
composites are provided having macro-dispersion level of the
particulate filler, molecular weight of the elastomer, particulate
loading level choice of particulate filler (including, for example,
carbon black fillers of exceptionally high surface area and low
structure) and/or other characteristics not previously achieved. In
that regard, the methods and apparatus disclosed here can achieve
excellent macro-dispersion, even of certain fillers, such as carbon
blacks having a structure to surface area ratio DBP:CTAB less than
1.2 and even less than 1, in elastomers such as natural rubber,
with little or no degradation of the molecular weight of the
elastomer. In accordance with yet other aspects of the invention,
intermediate products are provided as well as final products which
are formed of the elastomer composites produced by the method or
apparatus disclosed here.
[0020] In accordance with another aspect, novel elastomer
composites are provided, comprising a particulate filler dispersed
in natural rubber, the macro-dispersion level of the filler in the
elastomer composite being less than about 0.2% undispersed area,
preferably less than about 0.1% undispersed area. Consistent with
the discussion above, macro-dispersion here means the
macro-dispersion D (%) of the carbon black measured as percent
undispersed area for defects larger than 10 microns. In natural
rubber masterbatch and other elastomer composites disclosed here,
the molecular weight of the natural rubber, that is, the MW.sub.sol
(weight average) of the sol portion, preferably is at least about
300,000, more preferably at least about 400,000, being in certain
preferred embodiments between 400,000 and 900,000. The elastomer
composites optionally comprise extender oil, such as about 0 to 20
phr, more preferably about 0 to 10 phr extender oil, and/or other
ingredients such as are well known for optional use in compounding
natural rubber with carbon black filler. As discussed further below
in connection with certain preferred and exemplary embodiments, the
novel elastomer composites disclosed here can provide highly
desirable physical properties and performance characteristics.
Accordingly, the invention presents a significant technological
advance.
[0021] In accordance with another aspect, novel elastomer
composites are provided in which there is a novel, heretofore
unobtained, combination of properties, including certain
macro-dispersion level of the carbon black filler, molecular weight
of the natural rubber, carbon black loading level, carbon black
characteristics (including surface area and structure, e.g., carbon
black fillers of exceptionally high surface area and low structure)
and/or other characteristics. In accordance with various aspects of
the invention, masterbatch compositions and intermediate products
are provided, as well as final products which are formed of
them.
[0022] These and other aspects and advantages of various
embodiments of the invention will be further understood in view of
the following detailed discussion of certain preferred
embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The following discussion of certain preferred embodiments
will make reference to the appended drawings wherein:
[0024] FIG. 1 is a schematic flow chart illustration of the
apparatus and method for preparing elastomer masterbatch in
accordance with certain preferred embodiments;
[0025] FIG. 2 is an elevation view, partly schematic, of a
preferred embodiment consistent with the schematic flow chart
illustration of FIG. 1;
[0026] FIG. 3 is an elevation view, partially schematic, of an
alternative preferred embodiment consistent with the schematic flow
chart illustration of FIG. 1;
[0027] FIG. 4 is an elevation view, partially in section, of the
mix head/coagulum reactor assembly of the embodiment of FIG. 3;
[0028] FIG. 5 is an elevation view, partially in section,
corresponding to the view of FIG. 4, illustrating an alternative
preferred embodiment;
[0029] FIG. 6 is a section view taken through line 6-6 of FIG.
5;
[0030] FIG. 7 is a section view of a mix head suitable for use in
an alternative preferred embodiment;
[0031] FIG. 8 is a graph showing the surface area and structure
properties (CTAB and DBPA) of carbon blacks employed in certain
highly preferred masterbatch compositions in accordance with the
present invention;
[0032] FIGS. 9-25 are graphs showing the macro-dispersion, natural
rubber molecular weight and/or other characteristics of novel
elastomer composites in accordance with this invention comprising
carbon blacks shown in FIG. 8, in some cases along with data
relating to control samples for comparison, exemplifying the
significant improvements in physical characteristics and
performance properties achieved by the elastomer composites;
[0033] FIGS. 26-29 are graphs showing morphological properties of
carbon blacks, i.e., structure (DBPA) and surface area (CTAB), and
identifying regions or zones of carbon blacks (by such
morphological properties) which are suitable for specific product
applications; and
[0034] FIGS. 30 and 31 are graphs showing the macro-dispersion and
natural rubber molecular weight of novel elastomer composites in
accordance with this invention, along with control samples for
comparison.
[0035] It should be understood that the appended drawings are not
necessarily precisely to scale. Certain features may have been
enlarged or reduced for convenience or clarity of illustration.
Directional references used in the following discussion are based
on the orientation of components illustrated in the drawings unless
otherwise stated or otherwise clear from the context. In general,
apparatus in accordance with different embodiments of the invention
can be employed in various arrangements. It will be within the
ability of those skilled in the art, given the benefit of the
present disclosure, to determine appropriate dimensions and
orientations for apparatus of the invention employing routine
technical skills and taking into account well-known factors
particular to the intended application, such as desired production
volumes, material selection, duty cycle, and the like. Reference
numbers used in one drawing may be used in other drawings for the
same feature or element.
DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS
[0036] By virtue of the method and apparatus disclosed here,
elastomer masterbatch can be produced in a continuous flow process
involving mixture of elastomer latex and particulate filler fluids
at turbulence levels and flow control conditions sufficient to
achieve coagulation even without use of traditional coagulating
agents. In fact, it will be immediately recognized to be of great
commercial benefit that elastomer masterbatch crumb is achieved,
that is, coagulated latex is achieved, here without the need for
either intensive dry mastication of elastomer with filler or
exposing a liquid latex/particulate composition to a stream or tank
of coagulant. /Thus, in routine commercial implementation the cost
and complexity of employing acid coagulation solutions can be
avoided. Prior techniques involving premixing of latex and
particulate, such as in the above-mentioned Heller et al patent and
Hagopian et al patent do not even recognize the possibility of
achieving coagulation without exposing the latex/particulate
mixture to the usual coagulant solution with its attendant cost and
waste disposal disadvantages.
[0037] Feed rates of latex fluid and particulate filler fluid to
the mixing zone of the coagulum reactor can be precisely metered to
achieve high yield rates, with little free latex and little
undispersed filler in the product crumb at the discharge end of the
coagulum reactor. Without wishing to be bound by theory, it
presently is understood that a quasi-mono-phase system is
established in the mixing zone except that coagulum solids are
being formed there and/or downstream thereof in the coagulum zone.
Extremely high feed velocity of the particulate filler fluid into
the mixing zone of the coagulum reactor and velocity differential
relative the latex fluid feed are believed to be significant in
achieving sufficient turbulence, i.e., sufficiently energetic shear
of the latex by the impact of the particulate filler fluid jet for
thorough mixing and dispersion of the particulate into the latex
fluid and coagulation. High mixing energies yield product
masterbatch crumb with excellent dispersion, together with
controlled product delivery. The coagulum is created and then
formed into a desirable extrudate.
[0038] Certain preferred embodiments are discussed below, of
methods and apparatus for producing the novel elastomer composites
disclosed here. While various preferred embodiments of the
invention can employ a variety of different fillers and elastomers,
certain portions of the following detailed description of method
and apparatus aspects of the invention will, in some instances, for
convenience, describe their use primarily in producing masterbatch
comprising natural rubber and carbon black. It will be within the
ability of those skilled in the art, given the benefit of this
disclosure, to employ the method and apparatus disclosed here in
accordance with the principles of operation discussed below to
produce masterbatch comprising a number of alternative or
additional elastomers, fillers and other materials. In brief, such
methods for preparing elastomer masterbatch involve feeding
simultaneously a slurry of carbon black or other filler and a
natural rubber latex fluid or other suitable elastomer fluid to a
mixing zone of a coagulum reactor. A coagulum zone extends from the
mixing zone, preferably progressively increasing in cross-sectional
area in the downstream direction from an entry end to a discharge
end. The slurry is fed to the mixing zone preferably as a
continuous, high velocity jet of injected fluid, while the natural
rubber latex fluid is fed at relatively low velocity. The high
velocity, flow rate and particulate concentration of the filler
slurry are sufficient to cause mixture and high shear of the latex
fluid, flow turbulence of the mixture within at least an upstream
portion of the coagulum zone, and substantially completely
coagulate the elastomer latex prior to the discharge end.
Substantially complete coagulation can thus be achieved, in
accordance with preferred embodiments, without the need of
employing an acid or salt coagulation agent. The preferred
continuous flow method of producing the elastomer composites
comprises the continuous and simultaneous feeding of the latex
fluid and filler slurry to the mixing zone of the coagulum reactor,
establishing a continuous, semi-confined flow of a mixture of the
latex and filler slurry in the coagulum zone. Elastomer composite
crumb in the form of "worms" or globules are discharged from the
discharge end of the coagulum reactor as a substantially constant
flow concurrently with the on-going feeding of the latex and carbon
black slurry streams into the nixing zone of the coagulum reactor.
Notably, the plug-type flow and atmospheric or near atmospheric
pressure conditions at the discharge end of the coagulum reactor
are highly advantageous in facilitating control and collection of
the elastomer composite product, such as for immediate or
subsequent further processing steps. Feed rates of the natural
rubber latex fluid and carbon black slurry to the mixing zone of
the coagulum reactor can be precisely metered to achieve high yield
rates, with little free latex and little undispersed carbon black
in the product crumb at the discharge end of the coagulum reactor.
Without wishing to be bound by theory, it presently is understood
that a quasi-mono-phase system is established in the mixing zone
except that coagulum solids are being formed there and/or
downstream thereof in the coagulum zone. Extremely high feed
velocity of the carbon black slurry into the mixing zone of the
coagulum reactor and velocity differential relative the natural
rubber latex fluid feed are believed to be significant in achieving
sufficient turbulence, i.e., sufficiently energetic shear of the
latex by the impact of the particulate filler fluid jet for
thorough mixing and dispersion of the particulate into the latex
fluid and coagulation. High mixing energies yield the novel product
with excellent macro-dispersion, together with controlled product
delivery. The coagulum is created and then formed into a desirable
extrudate.
[0039] The aforesaid preferred apparatus and techniques for
producing the elastomer composites disclosed here are discussed in
conjunction with the appended drawings, wherein a continuous flow
method of producing elastomer masterbatch employs a continuous,
semi-confined flow of elastomer latex, for example, natural rubber
latex (field latex or concentrate) mixed with a filler slurry, for
example, an aqueous slurry of carbon black, in a coagulum reactor
forming an elongate coagulum zone which extends, preferably with
progressively increasing cross-sectional area, from an entry end to
a discharge end. The term "semi-confined" flow refers to a highly
advantageous feature. As used here the term is intended to mean
that the flow path followed by the mixed latex fluid and filler
slurry within the coagulum reactor is closed or substantially
closed upstream of the mixing zone and is open at the opposite,
downstream end of the coagulum reactor, that is, at the discharge
end of the coagulum reactor. Turbulence conditions in the upstream
portion of the coagulum zone are maintained in on-going, at least
quasi-steady state fashion concurrently with substantially plug
flow-type conditions at the open discharge end of the coagulum
reactor. The discharge end is "open" at least in the sense that it
permits discharge of coagulum, generally at or near atmospheric
pressure and, typically, by simple gravity drop (optionally within
a shrouded or screened flow path) into suitable collection means,
such as the feed hopper of a de-watering extruder. Thus, the
semi-confined flow results in a turbulence gradient extending
axially or longitudinally within at least a portion of the coagulum
reactor. Without wishing to be bound by theory, it presently is
understood that the coagulum zone is significant in permitting high
turbulence mixing and coagulation in an upstream portion of the
coagulum reactor, together with substantially plug-type discharge
flow of a solid product at the discharge end. Injection of the
carbon black or other filler slurry as a continuous jet into the
mixing zone occurs in on-going fashion simultaneously with ease of
collection of the elastomer masterbatch crumb discharged under
substantially plug-type flow conditions and generally ambient
pressure at the discharge end of the coagulum reactor. Similarly,
axial velocities of the slurry through the slurry nozzle into the
mixing zone and, typically, at the upstream end of the coagulum
zone are substantially higher than at the discharge end. Axial
velocity of the slurry will typically be several hundred feet per
second as it enters the mixing zone, preferably from a small bore,
axially oriented feed tube in accordance with preferred embodiments
discussed below. The axial velocity of the resultant flow at the
entry end of a coagulum reactor with expanding cross-sectional area
in a typical application may be, for example, 5 to 20 feet per
second, and more usually 7 to 15 feet per second. At the discharge
end, in contrast again, axial velocity of the masterbatch crumb
product being discharged there will in a typical application be
approximately 1 to 10 feet per second, and more generally 2 to 5
feet per second. Thus, the aforesaid semi-confined turbulent flow
achieves the highly significant advantage that natural rubber or
other elastomer latex is coagulated by mixture with carbon black or
other filler even in the absence of subsequent treatment in a
stream or tank of acid, salt or other coagulant solution, with
controlled, preferably quasi-molded product delivery from the
coagulum reactor for subsequent processing.
[0040] It should be understood in this regard that reference to the
coagulum reactor as being "open" at the discharge end is not
intended to mean that the discharge end is necessarily exposed to
view or easily accessed by hand. It may instead be permanently or
releasably attached to a collection device or subsequent processing
device, such as a diverter (discussed further below), dryer, etc.
The discharge end of the coagulum reactor is open in the important
sense that the turbulent flow within the coagulum zone of the
coagulum reactor, which is under high pressure and sealed against
any significant rearward (i.e., upstream) travel at the mixing
zone, is permitted to establish the aforesaid pressure and/or
velocity gradient as it travels toward and exits from the discharge
end.
[0041] It should also be recognized in this regard that the
turbulence of the flow lessens along the coagulum reactor toward
the discharge end. Substantial plug flow of a solid product is
achieved prior to the discharge end, dependent upon such factors as
percent of capacity utilization, selection of materials and the
like. Reference here to the flow being substantially plug flow at
or before the discharge end of the coagulum reactor should be
understood in light of the fact that the flow at the discharge end
is composed primarily or entirely of masterbatch crumb, that is,
globules or "worms" of coagulated elastomer masterbatch. The crumb
is typically quasi-molded to the inside shape of the coagulum zone
at the point along the coagulum zone at which flow became
substantially plug flow. The ever-advancing mass of "worms" or
globules advantageously have plug-type flow in the sense that they
are traveling generally or primarily axially toward the discharge
end and at any point in time in a given cross-section of the
coagulum zone near the discharge end have a fairly uniform
velocity, such that they are readily collected and controlled for
further processing. Thus, the fluid phase mixing aspect disclosed
here can advantageously be carried out at steady state or
quasi-steady state conditions, resulting in high levels of product
uniformity.
[0042] A preferred embodiment of the method and apparatus disclosed
here is illustrated schematically in FIG. 1. Those skilled in the
art will recognize that the various aspects of system
configuration, component selection and the like will depend to some
extent on the particular characteristics of the intended
application. Thus, for example, such factors as maximum system
through-put capacity and material selection flexibility will
influence the size and layout of system components. In general,
such considerations will be well within the ability of those
skilled in the art given the benefit of the present disclosure. The
system illustrated in FIG. 1 is seen to include means for feeding
natural rubber latex or other elastomer latex fluid at low pressure
and low velocity continuously to a mixing zone of a coagulum
reactor. More particularly, a latex pressure tank 10 is shown, to
hold the feed supply of latex under pressure. Alternatively, a
latex storage tank can be used, equipped with a peristaltic pump or
series of pumps or other suitable feed means adapted to hold
elastomer latex fluid to be fed via feed line 12 to a mixing zone
of a coagulum reactor 14. Latex fluid in tank 10 may be held under
air or nitrogen pressure or the like, such that the latex fluid is
fed to the mixing zone at a line pressure of preferably less than
10 psig, more preferably about 2-8 psig, and typically about 5
psig. The latex feed pressure and the flow lines, connections,
etc., of the latex feed means should be arranged to cause shear in
the flowing latex fluid as low as reasonably possible. Preferably
all flow lines, for example, are smooth, with only large radius
turns, if any, and smooth or faired line-to-line interconnections.
The pressure is selected to yield the desired flow velosity into
the mixing zone; an example of a useful flow velocity is no more
than about 12 feet per second.
[0043] Suitable elastomer latex fluids include both natural and
synthetic elastomer latices and latex blends. The latex must, of
course, be suitable for coagulation by the selected particulate
filler and must be suitable for the intended purpose or application
of the final rubber product. It will be within the ability of those
skilled in the art to select suitable elastomer latex or a suitable
blend of elastomer latices for use in the methods and apparatus
disclosed here, given the benefit of this disclosure. Exemplary
elastomers include, but are not limited to, rubbers, polymers
(e.g., homopolymers, copolymers and/or terpolymers) of
1,3-butadiene, styrene, isoprene, isobutylene,
2,3-dimethyl-1,3-butadiene- , acrylonitrile, ethylene, and
propylene and the like. The elastomer may have a glass transition
temperature (Tg) as measured by differential scanning calorimetry
(DSC) ranging from about -120.degree. C. to about 0.degree. C.
Examples include, but are not limited to, styrene-butadiene rubber
(SBR), natural rubber and its derivatives such as chlorinated
rubber, polybutadiene, polyisoprene, poly(stryene-co-butadiene) and
the oil extended derivatives of any of them. Blends of any of the
foregoing may also be used. The latex may be in an aqueous carrier
liquid. Alternatively, the liquid carrier may be a hydrocarbon
solvent. In any event the elastomer latex fluid must be suitable
for controlled continuous feed at appropriate velocity, pressure
and concentration into the mixing zone. Particular suitable
synthetic rubbers include: copolymers of from about 10 to about 70
percent by weight of styrene and from about 90 to about 30 percent
by weight of butadiene such as copolymer of 19 parts styrene and 81
parts butadiene, a copolymer of 30 parts styrene and 70 parts
butadiene, a copolymer of 43 parts styrene and 57 parts butadiene
and a copolymer of 50 parts styrene and 50 parts butadiene;
polymers and copolymers of conjugated dienes such as polybutadiene,
polyisoprene, polychloroprene, and the like, and copolymers of such
conjugated dienes with an ethylenic group containing monomer
copolymerizable therewith such as styrene, methyl styrene,
chlorostyrene, acrylonitrile, 2-vinyl-pyridine,
5-methyl-2-vinylpyridine, 5-ethyl-2-vinylpyridine,
2-methyl-5-vinylpyridine, alkyl-substituted acrylates, vinyl
ketone, methyl isopropenyl ketone, methyl vinyl either,
alphamethylene carboxylic acids and the esters and amides thereof
such as acrylic acid and dialkylacrylic acid amide. Also suitable
for use herein are copolymers of ethylene and other high alpha
olefins such as propylene, butene-1 and pentene-1. As noted further
below, the rubber compositions of the present invention can
contain, in addition to the elastomer and filler, curing agents, a
coupling agent, and optionally, various processing aids, oil
extenders and antidegradents.
[0044] In that regard, it should be understood that the elastomer
composites disclosed here include vulcanized compositions (VR),
thermoplastic vulcanizates (TPV), thermoplastic elastomers (TPE)
and thermoplastic polyolefins (TPO). TPV, TPE, and TPO materials
are further classified by their ability to be extruded and molded
several times without loss of performance characteristics. Thus, in
making the elastomer composites one or more curing agents such as,
for example, sulfur, sulfur donors, activators, accelerators,
peroxides, and other systems used to effect vulcanization of the
elastomer composition may be used.
[0045] Where the elastomer latex comprises natural rubber latex,
the natural rubber latex can comprise field latex or latex
concentrate (produced, for example, by evaporation, centrifugation
or creaming). The natural rubber latex must, of course, be suitable
for coagulation by the carbon black. The latex is provided
typically in an aqueous carrier liquid. Alternatively, the liquid
carrier may be a hydrocarbon solvent. In any event, the natural
rubber latex fluid must be suitable for controlled continuous feed
at appropriate velocity, pressure and concentration into the mixing
zone. The well known instability of natural rubber latex is
advantageously accommodated, in that it is subjected to relatively
low pressure and low shear throughout the system until it is
entrained into the aforesaid semi-confined turbulent flow upon
encountering the extraordinarily high velocity and kinetic energy
of the carbon black slurry in the mixing zone. In certain preferred
embodiments, for example, the natural rubber is fed to the mixing
zone at a pressure of about 5 psig, at a feed velocity in the range
of about 3-12 ft. per second, more preferably about 4-6 ft. per
second. Selection of a suitable latex or blend of latices will be
well within the ability of those skilled in the art given the
benefit of the present disclosure and the knowledge of selection
criteria generally well recognized in the industry.
[0046] The particulate filler fluid, for example, carbon black
slurry, is fed to the mixing zone at the entry end of coagulum
reactor 14 via feed line 16. The slurry may comprise any suitable
filler in a suitable carrier fluid. Selection of the carrier fluid
will depend largely upon the choice of particulate filler and upon
system parameters. Both aqueous and non-aqueous liquids may be
used, with water being preferred in many embodiments in view of its
cost, availability and suitability of use in the production of
carbon black and certain other filler slurries.
[0047] When a carbon black filler is used, selection of the carbon
black will depend largely upon the intended use of the elastomer
masterbatch product. Optionally, the carbon black filler can
include also any material which can be slurried and fed to the
mixing zone in accordance with the principles disclosed here.
Suitable additional particulate fillers include, for example,
conductive fillers, reinforcing fillers, fillers comprising short
fibers (typically having an L/D aspect ratio less than 40), flakes,
etc. Thus, exemplary particulate fillers which can be employed in
producing elastomer masterbatch in accordance with the methods and
apparatus disclosed here, are carbon black, fumed silica,
precipitated silica, coated carbon black, chemically functionalized
carbon blacks, such as those having attached organic groups, and
silicon-treated carbon black, either alone or in combination with
each other. Suitable chemically functionalized carbon blacks
include those disclosed in International Application No.
PCT/US95/16194 (WO9618688), the disclosure of which is hereby
incorporated by reference. In silicon-treated carbon black, a
silicon containing species such as an oxide or carbide of silicon,
is distributed through at least a portion of the carbon black
aggregate as an intrinsic part of the carbon black. Conventional
carbon blacks exist in the form of aggregates, with each aggregate
consisting of a single phase, which is carbon. This phase may exist
in the form of a graphitic crystallite and/or amorphous carbon, and
is usually a mixture of the two forms. As discussed elsewhere
herein, carbon black aggregates may be modified by depositing
silicon-containing species, such as silica, on at least a portion
of the surface of the carbon black aggregates. The result may be
described as silicon-coated carbon blacks. The materials described
herein as silicon-treated carbon blacks are not carbon black
aggregates which have been coated or otherwise modified, but
actually represent a different kind of aggregate. In the
silicon-treated carbon blacks, the aggregates contain two phases.
One phase is carbon, which will still be present as graphitic
crystallite and/or amorphous carbon, while the second phase is
silica (and possibly other silicon-containing species). Thus, the
silicon-containing species phase of the silicon-treated carbon
black is an intrinsic part of the aggregate; it is distributed
throughout at least a portion of the aggregate. It will be
appreciated that the multiphase aggregates are quite different from
the silica-coated carbon blacks mentioned above, which consist of
pre-formed, single phase carbon black aggregates having
silicon-containing species deposited on their surface. Such carbon
blacks may be surface-treated in order to place a silica
functionality on the surface of the carbon black aggregate. In this
process, an existing aggregate is treated so as to deposit or coat
silica (as well as possibly other silicon-containing species) on at
least a portion of the surface of the aggregate. For example, an
aqueous sodium silicate solution may be used to deposit amorphous
silica on the surface of carbon black aggregates in an aqueous
slurry at high pH, such as 6 or higher, as discussed in Japanese
Unexamined Laid-Open (Kokai) Publication No. 63-63755. More
specifically, carbon black may be dispersed in water to obtain an
aqueous slurry consisting, for example, of about 5% by weight
carbon black and 95% by weight water. The slurry is heated to above
about 70.degree. C., such as to 85-95.degree. C., and the pH
adjusted to above 6, such as to a range of 10-11, with an alkali
solution. A separate preparation is made of sodium silicate
solution, containing the amount of silica which is desired to be
deposited on the carbon black, and an acid solution to bring the
sodium silicate solution to a neutral pH. The sodium silicate and
acid solutions are added dropwise to the slurry, which is
maintained at its staring pH value with acid or alkali solution as
appropriate. The temperature of the solution is also maintained. A
suggested rate for addition of the sodium silicate solution is to
calibrate the dropwise addition to add about 3 weight percent
silicic acid, with respect to the total amount of carbon black, per
hour. The slurry should be stirred during the addition, and after
its completion for from several minutes (such as 30) to a few hours
(i.e., 2-3). In contrast, silicon-treated carbon blacks may be
obtained by manufacturing carbon black in the presence of
volatizable silicon-containing compounds. Such carbon blacks are
preferably produced in a modular or "staged" furnace carbon black
reactor having a combustion zone followed by a zone of converging
diameter, a feed stock injection zone with restricted diameter, and
a reaction zone. A quench zone is located downstream of the
reaction zone. Typically, a quenching fluid, generally water, is
sprayed into the stream of newly formed carbon black particles
flowing from the reaction zone. In producing silicon-treated carbon
black, the aforesaid volatizable silicon-containing compound is
introduced into the carbon black reactor at a point upstream of the
quench zone. Useful compounds are volatizable compounds at carbon
black reactor temperatures. Examples include, but are not limited
to, silicates such as tetraethoxy orthosilicate (TEDS) and
tetramethoxy orthosilicate, silanes such as, tetrachloro silane,
and trichloro methylsilane; and colatile silicone polymers such as
octamethylcyclotetrasiloxane (OMTS). The flow rate of the
volatilizable compound will determine the weight percent of silicon
in the treated carbon black. The weight percent of silicon in the
treated carbon black typically ranges from about 0.1 percent to 25
percent, preferably about 0.5 percent to about 10 percent, and more
preferably about 2 percent to about 6 percent. The volatizable
compound may be pre-mixed with the carbon black-forming feed stock
and introduced with the feed stock into the reaction zone,
Alternatively, the volatizable compound may be introduced to the
reaction zone separately, either upstream or downstream from the
feed stock injection point.
[0048] As noted above, additives may be used, and in this regard
coupling agents useful for coupling silica or carbon black should
be expected to be useful with the silicon-treated carbon blacks.
Carbon blacks and numerous additional suitable particulate fillers
are commercially available and are known to those skilled in the
art.
[0049] Selection of the particulate filler or mixture of
particulate fillers will depend largely upon the intended use of
the elastomer masterbatch product. As used here, particulate filler
can include any material which can be slurried and fed to the
mixing zone in accordance with the principles disclosed here.
Suitable particulate fillers include, for example, conductive
fillers, reinforcing fillers, fillers comprising short fibers
(typically having an L/D aspect ratio less than 40), flakes, etc.
In addition to the carbon black and silica-type fillers mentioned
above, fillers can be formed of clay, glass, polymer, such as
aramid fiber, etc. It will be within the ability of those skilled
in the art to select suitable particulate fillers for use in the
method and apparatus disclosed here given the benefit of the
present disclosure, and it is expected that any filler suitable for
use in elastomer compositions may be incorporated into the
elastomer composites using the teachings of the present disclosure.
Of course, blends of the various particulate fillers discussed
herein may also be used
[0050] Preferred embodiments of the invention consistent with FIG.
1 are especially well adapted to preparation of particulate filler
fluid comprising aqueous slurries of carbon black. In accordance
with known principles, it will be understood that carbon blacks
having lower surface area per unit weight must be used in higher
concentration in the particulate slurry to achieve the same
coagulation efficacy as lower concentrations of carbon black having
higher surface area per unit weight. Agitated mixing tank 18
receives water and carbon black, e.g., optionally pelletized carbon
black, to prepare an initial mixture fluid. Such mixture fluid
passes through discharge port 20 into fluid line 22 equipped with
pumping means 24, such as a diaphragm pump or the like. Line 28
passes the mixture fluid to colloid mill 32, or alternatively a
pipeline grinder or the like, through intake port 30. The carbon
black is dispersed in the aqueous carrier liquid to form a
dispersion fluid which is passed through outlet port 31 and fluid
line 33 to a homogenizer 34. Pumping means 36, preferably
comprising a progressing cavity pump or the like is provided in
line 33. Homogenizer 34 more finely disperses the carbon black in
the carrier liquid to form the carbon black slurry which is fed to
the mixing zone of the coagulum reactor 14. It has an inlet port 37
in fluid communication with line 33 from the colloid mill 32. The
homogenizer 34 may preferably comprise, for example, a
Microfluidizer.RTM. system commercially available from
Microfluidics International Corporation (Newton, Mass., USA). Also
suitable are homogenizers such as models MS18, MS45 and MC120
Series homogenizers available from the APV Homogenizer Division of
APV Gaulin, Inc. (Wilmington, Mass., USA). Other suitable
homogenizers are commercially available and will be apparent to
those skilled in the art given the benefit of the present
disclosure. Typically, carbon black in water prepared in accordance
with the above described system will have at least about 90%
agglomerates less than about 30 microns, more preferably at least
about 90% agglomerates less than about 20 microns in size.
Preferably, the carbon black is broken down to an average size of
5-15 microns, e.g., about 9 microns. Exit port 38 passes the carbon
black slurry from the homogenizer to the mixing zone through feed
line 16. The slurry may reach 10,000 to 15,000 psi in the
homogenizer step and exit the homogenizer at about 600 psi or more.
Preferably, a high carbon black content is used to reduce the task
of removing excess water or other carrier Typically, about 10 to 30
weight percent carbon black is preferred. Those skilled in the art
will recognize, given the benefit of this disclosure, that the
carbon black content (in weight percent) of the slurry and the
slurry flow rate to the mixing zone should be coordinated with the
natural rubber latex flow rate to the mixing zone to achieve a
desired carbon black content (in phr) in the masterbatch. The
carbon black content will be selected in accordance with known
principles to achieve material characteristics and performance
properties suited to the intended application of the product.
Typically, for example, carbon blacks of CTAB value 10 or more are
used in sufficient amount to achieve carbon black content in the
masterbatch of at least about 30 phr.
[0051] The slurry preferably is used in masterbatch production
immediately upon being prepared. Fluid conduits carrying the slurry
and any optional holding tanks and the like, should establish or
maintain conditions which substantially preserve the dispersion of
the carbon black in the slurry. That is, substantial reaglomeration
or settling out of the particulate filler in the slurry should be
prevented or reduced to the extent reasonably practical. Preferably
all flow lines, for example, are smooth, with smooth line-to-line
interconnections. Optionally, an accumulator is used between the
homogenizer and the mixing zone to reduce fluctuations in pressure
or velocity of the slurry at the slurry nozzle tip in the mixing
zone.
[0052] Natural rubber latex fluid or other elastomer latex fluid
passed to the mixing zone via feed line 12 and carbon black slurry
fed to the mixing zone via feed line 16 under proper process
parameters as discussed above, can produce a novel elastomer
composite, specifically, elastomer masterbatch crumb. Means may
also be provided for incorporating various additives into the
elastomer masterbatch. An additive fluid comprising one or more
additives may be fed to the mixing zone as a separate feed stream.
One or more additives also may be pre-mixed, if suitable, with the
carbon black slurry or, more typically, with the elastomer latex
fluid. Additives also can be mixed into the masterbatch
subsequently, e.g., by dry mixing techniques. Numerous additives
are well known to those skilled in the art and include, for
example, antioxidants, antiozonants, plasticizers, processing aids
(e.g., liquid polymers, oils and the like), resins,
flame-retardants, extender oils, lubricants, and a mixture of any
of them. The general use and selection of such additives is well
known to those skilled in the art. Their use in the system
disclosed here will be readily understood with the benefit of the
present disclosure. In accordance with certain alternative
embodiments, curative also can be incorporated in like manner, to
produce a curable elastomer composite which may be referred to as a
curable base compound.
[0053] The mixing zone/coagulum zone assembly is discussed in more
detail below. The elastomer masterbatch crumb is passed from the
discharge end of coagulum reactor 14 to suitable drying apparatus.
In the preferred embodiment of FIG. 1 the masterbatch crumb
undergoes multi-stage drying. It is passed first to a de-watering
extruder 40 and then via conveyor or simple gravity drop or other
suitable means 41 to a drying extruder 42. In routine preferred
embodiments consistent with that illustrated in FIG. 1 producing
natural rubber masterbatch with carbon black filler, the
de-watering/drying operation will typically reduce water content to
about 0 to 1 weight percent, more preferably 0.0 to 0.5 weight
percent. Suitable dryers are well known and commercially available,
including for example, extruder dryers, fluid bed dryers, hot air
or other oven dryers, and the like, such as French Mills available
from the French Oil Machinery Co., (Piqua, Ohio, USA).
[0054] Dried masterbatch crumb from drying extruder 42 is carried
by a cooling conveyor 44 to a baler 46. The baler is an optional,
advantageous feature of the apparatus of FIG. 1, wherein the dried
masterbatch crumb is compressed within a chamber into form-stable
compressed blocks or the like. Typically, 25 to 75 pound quantities
of the elastomer masterbatch are compressed into blocks or bales
for transport, further processing, etc. Alternatively, the product
is provided as pellets, for example, by chopping the crumb.
[0055] The dimensions and particular design features of the
coagulum reactor 14, including the mixing zone/coagulum zone
assembly, suitable for an embodiment in accordance with FIG. 1,
will depend in part on such design factors as the desired
throughput capacity, the selection of materials to be processed,
etc. One preferred embodiment is illustrated in FIG. 2 wherein a
coagulum reactor 48 has a mix head 50 attached to a coagulum zone
52 with a fluid-tight seal at joint 54. FIG. 2 schematically
illustrates a first subsystem 56 for feeding elastomer latex to the
mixing zone, subsystem 57 for feeding carbon black slurry or other
particulate filler fluid to the mixing zone, and subsystem 58 for
feeding an optional additive fluid, pressurized air, etc. to the
mixing zone. The mix head 50 is seen to have three feed channels
60, 61, 62. Feed channel 60 is provided for the natural rubber
latex fluid and feed channel 62 is provided for direct feed of gas
and/or additive fluid. In connection with preferred embodiments
employing direct injection of additives, significant advantage is
achieved in connection with hydrocarbon additives or, more
generally, non-water miscible additives. While it is well known to
employ emulsion intermediates to create additive emulsions suitable
for pre-blending with an elastomer latex, preferred embodiments in
accordance with the present disclosure employing direct injection
of additives can eliminate not only the need for emulsion
intermediates, but also the equipment such as tanks, dispersing
equipment, etc. previously used in forming the emulsions.
Reductions in manufacturing cost and complexity can, therefore, be
achieved. As discussed further below, the feed channel 61 through
which slurry is fed to the mixing zone is preferably coaxial with
the mixing zone and the coagulum zone of the coagulum reactor.
While only a single feed channel is shown to receive the elastomer
latex fluid, any suitable number of feed channels may be arranged
around the central feed channel through which the slurry is fed to
the mixing zone. Thus, for example, in the embodiment of FIG. 2 a
fourth feed channel could be provided through which ambient air or
high pressure air or other gas is fed to the mixing zone.
Pressurized air may be injected likewise with the slurry through
the central axial feed channel 61. Auxiliary feed channels can be
temporarily or permanently sealed when not in use.
[0056] The coagulum zone 52 of the coagulum reactor 48 is seen to
have a first portion 64 having an axial length which may be
selected depending upon design objectives for the particular
application intended. Optionally, the coagulum zone may have a
constant cross-sectional area over all or substantially all of its
axial length. Thus, for example, the coagulum reactor may define a
simple, straight tubular flow channel from the mixing zone to the
discharge end. Preferably, however, for reasons discussed above,
and as seen in the preferred embodiment illustrated in the
drawings, the cross-sectional area of the coagulum zone 52
increases progressively from the entry end 66 to discharge end 68.
More specifically, the cross-sectional area increases in the
longitudinal direction from the entry end to the discharge end. In
the embodiment of FIG. 2, the coagulum zone increases in
cross-sectional area progressively in the sense that it increases
continuously following constant cross-sectional portion 64.
References to the diameter and cross-sectional area of the coagulum
reactor (or, more properly, the coagulum zone defined within the
coagulum reactor) and other components, unless stated otherwise,
are intended to mean the cross-sectional area of the open flow
passageway and the inside diameter of such flow passageway.
[0057] Elastomer composite, specifically, coagulated elastomer
latex in the form of masterbatch crumb 72, is seen being discharged
from the coagulum reactor 48 through a diverter 70. Diverter 70 is
an adjustable conduit attached to the coagulum reactor at discharge
end 68. It is adjustable so as to selectively pass the elastomer
masterbatch crumb 72 to any of various different receiving sites.
This feature advantageously facilitates removal of masterbatch
crumb from the product stream, for example, for testing or at the
beginning of a production run when initial process instability may
result temporarily in inferior product. In addition, the diverter
provides design flexibility to direct product from the coagulum
reactor to different post-processing paths. In accordance with the
preferred embodiment of FIG. 1, the masterbatch crumb 72 being
discharged from coagulum reactor 48 through diverter 70 is seen to
be received by a drier 40.
[0058] The cross-sectional dimension of coagulum reactor 48 is seen
to increase at an overall angle a between entry end 66 and
discharge end 68. Angle .alpha. is greater than 0.degree. and in
preferred embodiments is less than 45.degree., more preferably less
than 15.degree., most preferably from 0.5.degree. to 5.degree.. The
angle .alpha. is seen to be a half angle, in that it is measured
from the central longitudinal axis of the coagulum zone to a point
A at the outer circumference of the coagulum zone at the end of the
coagulum reactor. In this regard, it should be understood that the
cross-sectional area of the upstream portion of the coagulum
reactor, that is, the portion near the entry end 66, preferably
increases sufficiently slowly to achieve quasi-molding of the
coagulum in accordance with the principles discussed above. Too
large an angle of expansion of the coagulum zone may result in the
elastomer masterbatch not being produced in desirable crumb form of
globules or worms and simply spraying through the coagulum reactor.
Increasing the bore of the coagulum reactor too slowly can result,
in certain embodiments, in backup or clogging of the feeds and
reaction product into the mix head. In a downstream portion of the
coagulum zone, wherein the latex has been substantially coagulated
and flow has become essentially plug flow, the coagulum zone may
extend either with or without increase in cross-sectional area.
Thus, reference here to the coagulum zone in preferred embodiments
having a progressively increasing cross-sectional area should be
understood to refer primarily to that portion of the coagulum zone
wherein flow is not substantially plug flow.
[0059] The cross-sectional area of the coagulum zone (that is, at
least the upstream portion thereof; as discussed immediately above)
may increase in step-wise fashion, rather than in the continuous
fashion illustrated in the embodiment of FIG. 2. In the embodiment
illustrated in FIG. 3, a continuous flow system for production of
elastomer masterbatch in accordance with the method and apparatus
disclosed here, is seen to include a mix head/coagulum zone
assembly wherein the cross-sectional area of the coagulum zone
increases in step-wise fashion. Preferably, the individual sections
of the coagulum zone in such a step-wise embodiment have a faired
connection to adjacent sections. That is, they combine to form a
smooth and generally continuous coagulum zone surface, as opposed,
for example, to a sharp or instantaneous increase in diameter from
one section to the next. The coagulum zone of FIG. 3 increases in
three steps, such that there are four different sections or
sub-zones 74-77. Consistent with the design principles discussed
immediately above, the cross-sectional area of coagulum zone 53
increases from the entry end 66 to point A at the discharge end 68
at an overall angle which achieves the necessary flow control in
the upstream portion of the coagulum reactor. The first section 74
can be taken as including (a) the constant diameter portion of the
mix head 50 immediately downstream of the mixing zone, and (b) the
same or similar diameter portion connected thereto at joint 54 at
the entry end 66. This first section has a constant cross-sectional
diameter D, and an axial dimension or length L.sub.1. In this first
section 74 the length L.sub.1 should be greater than three times
the diameter D.sub.1, more preferably greater than five times
D.sub.1, and most preferably from about 12 to 18 times D.sub.1.
Typically, this section will have a length of about fifteen times
D.sub.1. Each subsequent section preferably has a constant
cross-sectional dimension and cross-sectional area approximately
double that of the preceding (i.e., upstream) section. Thus, for
example, section 75 has a constant cross-sectional dimension and a
cross-sectional area which is twice that of section 74. Similarly,
the cross-sectional area of section 76 is double that of section
75, and the cross-sectional area of section 77 is double that of
section 76. In each of sections 75-77, the length is preferably
greater than three times its diameter, more preferably about three
to seven times its diameter and generally about five times its
diameter. Thus, for example, in section 76 longitudinal dimension
L.sub.3 is preferably about five times its diameter D.sub.3.
[0060] A mix head and coagulum zone assembly corresponding to the
embodiment of FIG. 3 is shown in FIG. 4 partially in section view.
Mix head 50 is integral with coagulum zone extender 53 via joint
54. It defines a mixing zone wherein multiple feed channels 60, 61,
62 form a junction, with an elongate, substantially cylindrical
channel 80 substantially coaxial with the coagulum zone portion
within extender 53. It will be recognized that it is not essential
to the operability of the method and apparatus disclosed here, to
precisely define the boundaries of the mixing zone and/or coagulum
zone. Numerous variations are possible in the design of the flow
channels junction area, as will be apparent to those skilled in the
art given the benefit of the present disclosure. In that regard, as
a generally preferred guideline, in embodiments of the type
illustrated in FIG. 4, for example, the slurry tip 67 generally is
upstream of the fling of cylindrical portion 80, being
approximately centered longitudinally in the junction of the feed
channels. In such embodiments, preferably, the minimum
cross-sectional area defined by the imaginary cone from the slurry
tip 67 to the circumferential perimeter at the beginning of the
cylindrical portion 80 is advantageously greater than, or at least
equal to, the cross-sectional area of the latex feed channel 60.
Preferably, both channel 80 and at least the upstream portion of
the coagulum zone wherein flow turbulence exists prior to
substantially complete coagulation of the elastomer latex, have a
circular cross-section.
[0061] The means for feeding carbon black slurry or other
particulate filler fluid is seen to comprise a feed tube 82
extending substantially coaxially with the mixing chamber to an
opening or slurry nozzle tip 67 which is open toward the coagulum
zone. This is a highly advantageous feature of the preferred
embodiments discussed here. The carbon black slurry, as noted
above, is fed to the mixing zone at very high velocity relative the
feed velocity of the latex, and the axial arrangement of narrow
bore feed tube 82 results in excellent development of flow
turbulence. The diameter D.sub.m of the channel 80 (which, as noted
above, is preferably substantially equal to the diameter D.sub.1 of
immediately following portion of section 74 of the coagulum zone)
preferably is at least twice the inside diameter of slurry feed
tube 82, more preferably about four to eight times the diameter of
feed tube 82, typically about seven to eight times that diameter.
Feed tube 82 is seen to form a fluid-tight seal with the entry port
83 at the upstream end of feed channel 61 of mix head 50. The
diameter of the axial feed tube 82 is determined largely by the
required volumetric flow rate and axial velocity of the slurry as
it passes through the slurry nozzle tip 67 into the mixing chamber.
The correct or required volume and velocity can be readily
determined by those skilled in the art given the benefit of this
disclosure, and will be a function, in part, of the concentration
and choice of materials. Embodiments such as that illustrated and
disclosed here, wherein the feed tube for the carbon black slurry
is removable, provide desirable flexibility in manufacturing
different masterbatch compositions at different times. The feed be
used in one production run can be removed and replaced by a larger
or smaller bore tube appropriate to a subsequent production. In
view of the pressure and velocity at which the slurry exits the
feed tube, it may be referred to as a spray or jet into the mixing
zone. This should be understood to mean in at least certain
embodiments, high speed injection of the slurry into an area
already substantially filled with fluid. Thus, it is a spray in the
sense of its immediate distribution as it passes through the slurry
nozzle tip, and not necessarily in the sense of free-flying
material droplets in a simple spreading trajectory.
[0062] The additional feed channels 60 and 62 are seen to form a
junction 84, 85, respectively, with feed channel 60 and downstream
channel 80 at an angle .beta.. The angle .beta. may in many
embodiments have a value from greater than 0.degree. to less than
180.degree.. Typically, .beta. may be, for example, from
30.degree.-90.degree.. It is desirable to avoid a negative
pressure, that is, cavitation of the latex fluid as it is entrained
by the high velocity slurry exiting at slurry nozzle tip 67, since
this may disadvantageously cause inconsistent mixing leading to
inconsistent masterbatch product. Air or other gas can be injected
or otherwise fed to the mixing zone to assist in breaking any such
vacuum. In addition, an expanded feed line for the natural rubber
latex leading to the entry port 86 of feed channel 60 is desirable
to act as a latex fluid reservoir. In the preferred embodiment of
FIG. 4, latex feed channel 60 intersects the mixing zone adjacent
slurry nozzle tip 67. Alternatively, however, the latex feed
channel can intersect the mixing channel upstream or downstream of
the slurry nozzle tip 67.
[0063] The carbon black slurry or other particulate filler fluid
typically is supplied to feed tube 82 at a pressure above about 300
psig, such as about 500 to 5000 psig, e.g. about 1000 psig.
Preferably the liquid slurry is fed into the mixing zone through
the slurry nozzle tip 67 at a velocity above 100 ft. per second,
preferably about 100 to about 800 ft. per second, more preferably
about 200 to 500 ft. per second, for example, about 350 feet per
second. Arrows 51 in FIG. 4 represent the general direction of flow
of the elastomer latex and auxiliary feed materials through feed
channels 60 and 62 into the channel 80 below slurry nozzle tip 67.
Thus, the slurry and latex fluids are fed to the mixing zones at
greatly different feed stream velocities, in accordance with the
numbers set forth above While not wishing to be bound by theory, it
presently is understood that the differential feed achieves latex
shear conditions in the mixing zone leading to good
macro-dispersion and coagulation.
[0064] An alternative preferred embodiment is illustrated in FIGS.
5 and 6 wherein the single axial feed tube 82 in the embodiment of
FIG. 4 is replaced by multiple axially extending feed tubes 90-92.
Even greater numbers of feed tubes may be employed, for example, up
to about 6 or 8 axially-extending feed tubes. Advantageously,
production flexibility is achieved by using different feed tubes of
different diameter for production of different formulations. Also,
multiple feed tubes can be used simultaneously to achieve good flow
turbulence within the mixing zone and coagulum zone of the coagulum
reactor.
[0065] An alternative embodiment of the mix head is illustrated in
FIG. 7. Mix head 150 is seen to define a mixing zone 179. An axial
feed channel 161 receives a feed tube 182 adapted to feed carbon
black slurry or other particulate filler fluid at high velocity
into the mixing chamber 179. It can be seen that the central bore
in feed tube 182 terminates at slurry nozzle tip 167. A constant
diameter nozzle land 168 is immediately upstream of slurry nozzle
tip 167, leading to a larger bore area 169. Preferably the axial
dimension of land 168 is about 2 to 6, e.g. about 5, times its
diameter. A second feed channel 160 forms a junction 184 with the
mixing zone 179 at a 90.degree. angle for feeding elastomer latex
fluid to the mixing zone. The cross-sectional diameter of the latex
fluid feed channel 160 is substantially larger than the
cross-sectional diameter of the slurry nozzle tip 167 and land 168.
Without wishing to be bound by theory, the axial elongation of
nozzle land 168, coupled with the expanded diameter bore section
upstream of the nozzle land, is believed to provide advantageous
stability in the flow of slurry through feed tube 182 into the
mixing zone 179. The bore of feed tube 182 is found to function
well with a 20.degree. chamfer, that is, conical area 169 which
expands in the upstream direction at about a 20.degree. angle.
Downstream of mixing zone 179 is an elongate coagulum zone.
Consistent with the principles discussed above, such coagulum zone
need be only marginally elongate. That is, its axial dimension need
be only marginally longer than its diameter. Preferably, however, a
progressively enlarged coagulum zone is used.
[0066] As discussed above, coagulation of the elastomer masterbatch
is substantially complete at or before the end of the coagulum
reactor. That is, coagulation occurs within the coagulum zone of
the coagulum reactor without the necessity of adding a stream of
coagulant solution or the like. This does not exclude the
possibility that some initial coagulation occurs in the mixing
zone. The mixing zone may be considered an extended portion of the
coagulum zone for this purpose. Also, reference to substantially
complete coagulation prior to the elastomer masterbatch exiting the
coagulum reactor is not meant to exclude the possibility of
subsequent processing and follow-on treatment steps, for any of
various purposes appropriate to the intended use of the final
product. In that regard, substantially complete coagulation in
preferred embodiments of the novel method disclosed here employing
natural rubber latex means that at least about 95 weight percent of
the rubber hydrocarbon of the latex is coagulated, more preferably
at least about 97 weight percent, and most preferably at least
about 99 weight percent is coagulated.
[0067] The method and apparatus disclosed and described here
produce elastomer composites having excellent physical properties
and performance characteristics. Novel elastomer composites of the
present invention include masterbatch compositions produced by the
above-disclosed method and apparatus, as well as intermediate
compounds and finished products made from such masterbatch
compositions. Notably, elastomer masterbatch can be produced using
natural rubber latex (latex concentrate or field latex), along with
various grades of carbon black filler, having excellent physical
properties and performance characteristics. Carbon blacks presently
in broad commercial use for such application as tire tread have
been used successfully, as well as carbon blacks heretofore
considered unsuitable for commercial use in known production
apparatus and methods. Those unsuitable because their high surface
area and low structure rendered them impractical to achieve
acceptable levels of macro-dispersion at routine commercial loading
levels for the carbon black and/or to preserve the molecular weight
of the elastomer are highly preferred for the novel elastomeric
masterbatch compositions disclosed here. Such elastomer composites
are found to have excellent dispersion of the carbon black in the
natural rubber, together with good preservation of the molecular
weight of the natural rubber. Moreover, these advantageous results
were achieved without the need for a coagulation step involving a
treatment tank or stream of acid solution or other coagulant. Thus,
not only can the cost and complexity of such coagulant treatments
be avoided, so too the need to handle effluent streams from such
operations.
[0068] Prior known dry mastication techniques could not achieve
equal dispersion of such fillers without significant molecular
weight degradation and, therefore, could not produce the novel
natural rubber masterbatch compositions made in accordance with
certain preferred embodiments of the present invention. In that
regard, novel elastomer composites are disclosed having excellent
macro-dispersion of the carbon black in the natural rubber, even of
carbon blacks having a structure to surface area ratio DBPA:CTAB
less than 1.2 and even less than 1.0, with high molecular weight of
the natural rubber. Known mixing techniques in the past did not
achieve such excellent macro-dispersion of carbon black without
significant molecular weight degradation of the natural rubber and,
therefore, did not produce the novel masterbatch compositions and
other elastomer composites of the present invention. Preferred
novel elastomer masterbatch compositions in accordance with this
disclosure, having carbon black macro-distribution levels not
heretofore achieved, can be used in place of prior known
masterbatch having poorer macro-dispersion. Thus, masterbatch
disclosed here can be incorporated into cured compounds in
accordance with known techniques. Such novel cured compounds are
found in preferred embodiments to have physical characteristics and
performance properties generally comparable to, and in some
instances significantly better than, those of otherwise comparable
cured compounds comprising masterbatch of poorer macro-dispersion.
Masterbatch can be produced in accordance with the present
invention, however, with reduced mixing time, reduced energy input,
and/or other cost savings.
[0069] Particularly with respect to certain preferred embodiments,
natural rubber latex and carbon black filler masterbatch can be
produced having excellent physical characteristics and performance
properties. Excellent macro-dispersion of the carbon black is
achieved, even using carbon blacks of exceptionally high surface
area and low structure, without the degree of degradation of the
natural rubber which would be caused by dry mastication for
sufficient time and at sufficient intensity levels to achieve the
same degree of carbon black dispersion. Especially advantageous in
this regard are novel natural rubber masterbatch compositions
wherein a high degree of dispersion is achieved, using carbon
blacks having structure to surface area ratio, DBPA: CTAB of less
than 1.2 and even less than 1.0. As used here, the carbon black
structure can be measured as the dibutyl phthalate adsorption
(DBPA) value, expressed as cubic centimeters of DBPA per 100 grams
carbon black, according to the procedure set forth in ASTM D2414.
The carbon black surface area can be measured as CTAB expressed as
square meters per gram of carbon black, according to the procedure
set forth in ASTM D3765-85. Novel natural rubber masterbatch is
achieved, therefore, having heretofore unachievable combinations of
physical characteristics such as molecular weight distribution and
filler dispersion levels, and/or incorporating heretofore
unsuitable fillers such as carbon black of extraordinarily high
surface area and low structure. The dispersion quality of natural
rubber masterbatch produced in accordance with the methods and
apparatus disclosed here can be demonstrated with reference to the
well known characteristics of MW.sub.sol (weight average) and
macro-dispersion. Specifically, the macro-dispersion level in
masterbatch produced in accordance with preferred embodiments is
significantly better than that in masterbatch of approximately
equal MW.sub.sol produced using dry mastication. Most notably, the
dispersion quality of these preferred embodiments does not depend
significantly on the morphology of the carbon black filler. It will
be recognized that other factors affecting the level of dispersion
achievable using the method and apparatus disclosed here, include
the concentration of the carbon black in the slurry, total energy
input into the slurry and energy input during mixing of the fluid
streams, etc.
[0070] The macro-dispersion quality of carbon black in natural
rubber masterbatch disclosed here is significantly better than that
in previously known masterbatch of approximately equal MW.sub.sol
(weight average). In some preferred embodiments of novel elastomer
composites, excellent carbon black distribution is achieved with
MW.sub.sol approximately that of natural rubber in the field latex
state, (e.g., approximately 1,000,000) a condition not previously
achieved. The dispersion quality advantage is especially
significant in the above mentioned preferred embodiments using
carbon black with low structure and high surface area, e.g., DBPA
less than 110 cc/100 g, CTAB greater than 45 to 65 m.sup.2/g, and
DBPA:CTAB less than 1.2 and preferably less than 1.0.
EXAMPLES
Test Procedures
[0071] The following test procedures were used in the examples and
comparisons presented below.
[0072] 1. Bound Rubber: A sample weighing 0.5 g..+-.0.025 g. is
weighed and placed in 100 ml. toluene in a sealed flask and stored
at ambient temperature for approximately 24 hours. The toluene is
then replaced with 100 ml. fresh toluene and the flask is stored
for 4 days. The sample is then removed from the solvent and
air-dried under a hood at ambient temperature for 24 hours. The
sample is then further dried in a vacuum oven at ambient
temperature for 24 hours. The sample is then weighed and the bound
rubber is calculated from the weight loss data.
[0073] 2 MW.sub.sol: As used in this disclosure and in the claims,
MW.sub.sol refer to weight average molecular weight of the sol
portion of the natural rubber. Standard GPC techniques for
molecular weight measurement were followed in accordance with the
following:
[0074] 2.1 Two 10 .mu.m 10.sup.6 .ANG. columns, a 10 .mu.m 500
.ANG. column and a 10 .mu.m mixed bed column from Polymer
Laboratories, UTK.
[0075] 2.2 UV detection at 215 nm.
[0076] 2.3 Solvent: Tetra hydro furan (THF)
[0077] 2.4 Concentration, nominally 2 mg/ml in TBF.
[0078] 2.5 Samples are left to dissolve in THF for 3 days,
stabilized with BHT.
[0079] 2.6 Solutions are centrifuged to separate any gel and the
supernatant is injected onto the column.
[0080] 2.7 Sample Preparations Sample preparation is designed to
prepare sol concentrations in the range of 0.5 to 0.05 percent by
weight to provide a good detector response for accurate measurement
of the molecular weight distribution. Depending on the filler
loading, sample weight is adjusted according to the following
formula:
sample wt.=(100+filler loading (phr))*20/100 mg+/-2 mg
[0081] Samples are placed in UV protected vials and dissolved in 4
mL of stabilized tetrahydrofuran (THF) containing 0.02%
butylated-hydroxyltolue- ne (BHT) for three days. The supernatant
from the dissolution step, containing mostly the sol portion, is
transferred to Teflon centrifuge tubes and centrifuged in an Avanti
30 (Beckman) centrifuge for 60 minutes at 26,000 revolutions per
minute (corresponding to a maximum field strength of 57,500 g). At
this field strength, a majority of the gel phase sediments allowing
a gel-free supernatant. This gel-free solution is diluted at 1:5,
again using stabilized THF. At this point, the samples are
transferred to GPC vials and placed inside a Waters 717
Auto-Sampler (Water Corporation, Milford, Mass., USA) in
preparation for the GPC testing.
[0082] Molecular Weight Determination The weight average molecular
weight of the sol portion MW.sub.sol is then determined. Using
Millenium software (available from Waters Corporation, Milford,
Mass., USA) a baseline is defined using a valley-to-valley mode
within the time increments of 15 and 35 minutes. This time
increment is appropriate for the column set described above in
paragraph 2.1 with the mobile phase flow rate set at 0.75 mL/min.
Once a reasonable baseline is established the distribution can be
determined. The elution time is converted to molecular weight.
Polystyrene solutions made from commercially available standards
(EasiCal:Polymer Laboratories, U.K.) are prepared containing a
series of molecular weights with very narrow distributions. The
conversion of polystyrene molecular weight to polyisoprene
molecular weight equivalents is based on the universal calibration
method of Benoit and coworkers. The hydrodynamic radius is
proportional to the product of the molecular weight times the
intrinsic viscosity. After converting the polystyrene molecular
weights to polyisoprene equivalents, the calibration curve relates
absolute molecular weight to elution time. The standards are run
under conditions identical to the samples, and the standards are
integrated to assign the appropriate molecular weight for a given
elution time, based on a best fit to the standards data. Once the
time based distribution is properly converted to molecular weight,
the appropriate molecular weight averages are calculated by the
Waters' Millenium software.
[0083] 3. Mooney Viscosity: Standard procedures were followed for
ML (1+4)(@100.degree. C.
[0084] 4. Test Sample Cure Conditions: Test pieces were cured to
150.degree. C. for the time periods indicated below:
[0085] 4.1 Tensile Sheet: 20 min.
[0086] 4.2 Resilience: 23 min.
[0087] 4.3 Hardness: 23 min.
[0088] 4.4 Heat Build-Up: 25 min.
[0089] 5. Dispersion: The Cabot Dispersion Chart method is used
with subjective evaluation of 50.times. optical micrographs. (ASTM
D2663 Method).
[0090] 6. Stress-Strain: Tested to BS903:A2 and ISO 37.
[0091] 7. Hardness: Tested to ISO 48 (1994), temperature 23.degree.
C.
[0092] 8. Resilience: Tested to BS903:A8 (1990), Method A,
temperature 23.degree. C. (8 mm molded disc test piece).
[0093] 9. Heat Buildup: Tested to ASTM D623, Method A.
[0094] 9.1 Start temperature: 23.degree. C.
[0095] 9.2 Static load: 24 lbs.
[0096] 9.3 Stroke: 0.225 inches.
[0097] 9.4 Frequency: 30 Hz.
[0098] 9.5 Run for 30 minutes.
[0099] 10. Tan .delta.: Measured on Rheometrics.RTM. model RDS II.
Reported values are maximums from strain sweeps. Strain sweeps at
0.degree., 30.degree., and 60.degree. C., 1 Hz, and 0.1% to 60%
strain.
[0100] 11. Crack Growth Resistance: Measured in accordance with
ASTM D3629-94
Example A
[0101] Elastomer masterbatch was produced in accordance with the
present invention. Specifically, an elastomer masterbatch was
produced comprising standard natural rubber field latex from
Malaysia with 52.5 phr filler consisting of carbon black of
commercial grade N234 available from Cabot Corporation. The
properties of the natural rubber field latex are provided in Table
1 below.
1TABLE 1 Natural Rubber Latex Properties ML Addi- % Dry % Total
Nitrogen Volatile (1 + 4) tives Rubber Solids % Ash ppm Fatty Acid
@ 100 C. 0.15% 28.4 34.2 0.38 0.366 0.052 68 HNS.sup.a 0.3% NH3,
ZnO, TMTD.sup.b .sup.aHNS: hydroxylamine neutral sulfate, Mooney
viscosity stabilizer. .sup.bZnO/TMTD: used for biological
preservation, typically 0.025% of 1:1 mixture.
[0102] The full compound formulation is set forth in Table 2 below,
and is representative of a commercial truck tire tread known to
have excellent resistance to reversion during cure.
2TABLE 2 Masterbatch Formulation Ingredient Parts by Wt. Rubber 100
Carbon Black 52.5 ZnO 4.0 Stearic acid 2.0 6PPD (antioxidant) 2.0
Sunproof Improved (wax) 2.0 Ennerflex 74 (aromatic oil) 3.0 Total
165.5
[0103] The elastomer masterbatch production apparatus was
substantially identical to the apparatus described above with
reference to FIGS. 1 and 7 of the drawings. The slurry nozzle tip
(see reference No 167 in FIG. 7) was 0.039 inch diameter with a
land (see reference No. 168 in FIG. 7) having an axial length of
0.2 inch. The coagulum zone was 0.188 inch diameter and had 0.985
inch axial length of constant diameter between the nixing zone and
its discharge end. Preparation of the masterbatch is described in
further detail immediately below.
[0104] 1. Carbon Black Slurry Preparation. Bags of carbon black
were mixed with deionized water in a carbon black slurry tank
equipped with an agitator. The agitator broke the pellets into
fragments and a crude slurry was formed with 12.5 wt. % carbon
black. During operation, this slurry was continually pumped by an
air diaphragm pump to a colloid mill for initial dispersion. The
slurry was then fed by a progressing cavity pump to a homogenizer,
specifically, a model M3 homogenizer from APV Gaulin, Inc. The
homogenizer produced a finely ground slurry. The slurry flow rate
from the homogenizer to the mixing zone was set by the homogenizer
speed, the homogenizer acting as a high-pressure positive
displacement pump. Slurry flow rate was monitored with a
Micromotion.RTM. mass flow meter. The carbon black slurry was fed
to the homogenizer at a pressure ranging from 50 to 100 psig and
the homogenization pressure was set at 4000 psig, such that the
slurry was introduced as a jet into the mixing zone at a flow rate
of 4.1 to 4.4 lb/min and at a velocity of about 130 ft/sec.
[0105] 2. Latex Delivery. The latex was charged to a 100 gallon
pressurized feed tank. Antioxidant emulsion was added to the latex
prior to charging. Antioxidants were added consisting of 0.3 phr
tris nonyl phenyl phosphite (TNPP) and 0.4 phr Santoflex.RTM. 134
(alkyl-aryl p-phenylene diamine mixture). Each of the antioxidants
was prepared as a 15 wt. % emulsion using 3 parts potassium oleate
per 100 parts antioxidant along with potassium hydroxide to adjust
the emulsion to a pH of approximately 10. Also, 3 phr extender oil
was added. Air pressure (51 psig) was used to move the latex from
the feed tank to the mixing zone of the coagulum reactor. The latex
flow rate was 3.2 to 3.4 lbs/min and about 3.8 feet per second, and
was automatically metered and controlled with a Micromotion.RTM.
mass flow meter and a rubber tube pinch valve. The desired carbon
black loading of a 52.5 phr was obtained by making proper ratio of
the latex feed rate to the carbon black slurry feed rate.
[0106] 3. Carbon Black and Latex Mixing. The carbon black slurry
and latex were mixed by entraining the latex into the carbon black
slurry. During entrainment, the carbon black was intimately mixed
into the latex and the mixture coagulated. Soft, wet spongy "worms"
of coagulum exited the coagulum reactor.
[0107] 4. Dewatering. The wet crumb discharged from the coagulum
reactor was about 79% water. The wet crumb was dewatered to about 5
to 10% moisture with a dewatering extruder (The French Oil Mill
Machinery Company; 31/2 in. diameter). In the extruder, the wet
crumb was compressed and water squeezed from the crumb and through
a slotted barrel of the extruder.
[0108] 5. Drying & Cooling. The dewatered crumb dropped into a
second extruder where it was again compressed and heated. Water was
flashed off upon expulsion of the crumb through the dieplate of the
extruder. Product exit temperature was approximately 300.degree. F.
and moisture content was about 0.5 to 1 wt. %. The hot, dry crumb
was rapidly cooled (approximately 20 seconds) to about 100.degree.
F. by a forced air vibrating conveyor. The resulting dry crumb had
about 66. wt. % rubber solids and about 33. wt. % carbon black.
Example B
[0109] A control masterbatch was prepared by dry mastication. The
control employed the same formulation as Example A (see Table 2
above), except that the natural rubber was SMR 10 rather than
latex. It was prepared by premastication of the rubber in a OOC
Banbury mixer (approximately 3 kg) at 50 rpm using 10 phr carbon
black. The premastication was performed for approximately 3 min. to
a total of 800 MJ/m.sup.3.
Comparisons of Example A and Example B
[0110] The masterbatch of Example A and the control masterbatch of
Example B were compounded in a two-stage mixing operation in a OOC
Banbury mixer (approximately 3 kg). Table 3 below sets forth the
mixing schedule for the first stage. It can be seen that the
Example A masterbatch followed a modified mixing schedule.
3TABLE 3 Stage 1 Mixing Schedules Time Example B (mm) Example A Dry
Mix Control 0.0 All ingredients Pre-Masticated Rubber 0.5 Carbon
Black and Oil 1.0 Sweep 1.5 Remaining Ingredients 2.0 2.5 Sweep 3.0
X dump at approx. 700 MJ/m.sup.3 dump at approx. 1,000
MJ/m.sup.3
[0111] In the second stage, curatives listed in Table 4 below were
added with a further mixing cycle of 500 MJ/m.sup.3.
4TABLE 4 Final Stage Curative Addition Ingredient Parts by Wt.
Stage 1 compound 165.5 Goodyear Winstay 100 (antioxidant) 1.0 TBBS
(sulfur accelerator) 1.8 Sulfur 10 Total 169.3
[0112] Thus, Banbury mixing energy for the compounding of Example A
masterbatch was about 53% of the Banbury mixing energy required for
the premastication and compounding of the control material of
Example B. Despite the reduced energy input, the Example A material
was found to have very good macro-dispersion, and the molecular
weight (weight average) of its sol portion MW.sub.sol was
substantially higher than that of the control. These data are
summarized in Table 5 below.
5TABLE 5 Compounding and Curing Data ML Mix Energy (MJ/m.sup.3) (1
+ 4, 100 C.) MW Sam- Pre- ple Masticate Stage 1 Final Total Stage 1
Final wt. av. Example 0 694 500 1,194 102 72 444,900 A Example 800
965 500 2,265 92 67 327,000 B
[0113] Additional testing results for the cured (unaged) Example A
and control material are set forth in Table 6 below.
6TABLE 6 Additional Test Data 100% 300% Modulus Modulus Tensile
Sample Hardness (MPa) (MPa) (MPa) Example A 71 2.82 16.1 28.7
Example B 72 3.12 16.2 28.5 Heat Elongation Build- at Resiliance Up
Max Tan Delta Sample Break (%) (%) (.degree. C.) 60.degree. C.
30.degree. C. 0.degree. C. Example 526 56.5 70.5 0.203 0.240 0.290
A Example 511 57.6 76.5 0.206 0.236 0.286 B
Example C
[0114] Elastomer masterbatch was produced in accordance with the
present invention. Specifically, an elastomer masterbatch was
produced comprising standard natural rubber field latex from
Malaysia with 55 phr filler consisting of carbon black of
commercial grade Regal.RTM. 660 available from Cabot Corporation.
The compound formulation (excluding minor ordinary latex additives)
is set forth in Table 7 below.
7TABLE 7 Masterbatch Formulation Ingredient Parts by Wt. Rubber 100
Carbon Black 55. Santoflex 134 (antioxidant) 0.4 TNPP (antioxidant)
0.3 Total 155.7
[0115] The elastomer masterbatch production apparatus was
substantially identical to the apparatus described above with
reference to FIGS. 1, 3 and 7 of the drawings. The slurry nozzle
tip (see reference No. 167 in FIG. 7) was 0.025 inch diameter with
a land (see reference No. 168 in FIG. 7) having an axial length of
0.2 inch. The coagulum zone (see No. 53 in FIG. 3) included a first
portion of 0.188 inch diameter and approximately 0.985 inch axial
length (being partly within the mix-head and party within the
extender sealed thereto); a second portion of 0.266 inch diameter
and 1.6 inch axial length; a third portion of 0.376 inch diameter
and 2.256 axial length; and a fourth portion of 0.532 inch diameter
and 3.190 inch axial length. In addition, there are axially short,
faired interconnections between the aforesaid portions. Preparation
of the masterbatch is described in further detail immediately
below.
[0116] 1. Carbon Black Slurry Preparation. Bags of carbon black
were mixed with deionized water in a carbon black slurry tank
equipped with an agitator. The agitator broke the pellets into
fragments and a crude slurry was formed with 14.9 wt. % carbon
black. The crude slurry was recirculated using a pipeline grinder.
During operation, this slurry was continually pumped by an air
diaphragm pump to a colloid mill for initial dispersion. The slurry
was then fed by a progressing cavity pump to a homogenizer,
specifically, Microfluidizer Model M210 from Microfluidics
International Corporation for pressurizing and shear, to produce a
finely ground slurry. The slurry flow rate from the microfluidizer
to the mixing zone was set by the microfluidizer speed, the
microfluidizer acting as a high-pressure positive displacement
pump. Slurry flow rate was monitored with a Micromotion.RTM. mass
flow meter. The carbon black slurry was fed to the microfluidizer
at a pressure of about 130 psig and the output pressure was set at
3000 psig to an accumulator set at 450 psig output pressure, such
that the slurry was introduced as a jet into the mixing zone at a
flow rate of about 3.9 lb/min and at a velocity of about 300
ft/sec.
[0117] 2. Latex Delivery. The latex was charged to a tank,
specifically, a 55 gallon feed drum. Antioxidant emulsion was added
to the latex prior to charging Antioxidants were added consisting
of 0.3 phr tris nonyl phenyl phosphite (TNPP) and 0.4 phr
Santoplex.RTM. 134 (alkyl-aryl p-phenylene diamine mixture). Each
of the antioxidants was prepared as a 40 wt. % emulsion using 4
parts potassium oleate per 100 parts antioxidant along with
potassium hydroxide to adjust the emulsion to a pH of approximately
10. A peristaltic pump was used to move the latex from the feed
tank to the mixing zone of the coagulum reactor. The latex flow
rate was 3.2 to 3.3 lbs/min and about 3.9 feet per second, and was
metered with a Endress+Hauser (Greenwood, Ind., USA) mass flow
meter. The desired carbon black loading of a 55 phr was obtained by
maintaining proper ratio of the latex feed rate to the carbon black
slurry feed rate.
[0118] 3. Carbon Black and Latex Mixing. The carbon black slurry
and latex were mixed by entraining the latex into the carbon black
slurry. During entrainment, the carbon black was intimately mixed
into the latex and the mixture coagulated. Soft, wet spongy "worms"
of coagulum exited the coagulum reactor.
[0119] 4. Dewatering. The wet crumb discharged from the coagulum
reactor was about 78% water. The wet crumb was dewatered to about
12 to 13% moisture with a dewatering extruder (The French Oil Mill
Machinery Company; 31/2 in. diameter). In the extruder, the wet
crumb was compressed and water squeezed from the crumb and through
a slotted barrel of the extruder.
[0120] 5. Drying & Cooling. The dewatered crumb dropped into a
second extruder where it was again compressed and heated. Water was
flashed off upon expulsion of the crumb through the dieplate of the
extruder. Product exit temperature was approximately 280.degree. F.
to 370.degree. F. and moisture content was about 0.3 to 0.4 wt. %.
The hot, dry crumb was rapidly cooled (approximately 20 seconds) to
about 100.degree. F. by a forced air vibrating conveyor.
Examples D and E
[0121] Two dry mix control masterbatches were prepared by dry
mastication. The controls employed the same formulation as Example
C (see Table 7 above), except that in Example D the rubber was RSS1
NR rather than latex. In Example E the rubber was SMR 10 NR Each
was prepared by premastication of the rubber in a BR Banbury mixer.
The rubber of Example D was masticated at 118 rpm for 10 minutes.
The rubber of Example E was masticated at 77 rpm for 4 minutes.
Comparison of Examples C, D and E
[0122] The masterbatch of Example C and the two control
masterbatches of Example D and E were compounded in a BR Banbury
mixer. Table 8 below sets forth the compounding schedules.
8TABLE 8 Compounding Schedules Stage II (Final) Masterbatch
Pre-Mastication Stage I Mixing Mixing Example C No No BR Banbury 77
rpm, 4.5 min. Example D BR Banbury BR Banbury BR Banbury 77 mixer
118 rpm, mixer 77 rpm, 3 rpm, 4.5 min. 10 min. min. Example E BR
Banbury BR Banbury BR Banbury 77 mixer 77 rpm, 4 mixer 77 rpm, 8
rpm, 4.5 min. min. min.
[0123] The compounding formulation is given in Table 9 below.
9TABLE 9 Stage H Curative Addition Ingredient Parts by Wt. Example
4 Masterbatch or 155 Example 5 or 6 Stage I Dry Mix Azo 66 (zinc
oxide) 4.0 Hystrene 5016 (stearic acid) 2.0 Santoflex 13
(antioxidant) 2.0 Sunproof Improved (wax) 2.0 Wingstay 100
(antioxidant) 1.0 Santocure NS (sulfur accelerator) 1.8 Sulfur 1.0
Total: 168.8
[0124] All three compounds exhibited well-behaved cure with minimal
reversion. Despite the reduced energy input, the Example C material
was found to have significantly better macro-dispersion than the
dry mix controls, and the molecular weight (weight average) of its
sol portion MW.sub.sol was substantially higher than that of the
controls. These data are summarized in Table 10 below.
10TABLE 10 Masterbatch and Compound Properties Example C Example D
Example E Masterbatch Properties Mooney Viscosity 125 124 126 ML(1
+ 4) @ 100 C. Bound Rubber 50 32 44 (%) MW aol (.times.10.sup.-6)
0.678 .466 .463 Percent .12 1.48 2.82 Undispersed Area (D%)
Compound Properties Hardness 62 65 62 100% Modulus 239 315 270
(psi) 300% Modulus 1087 1262 1216 (psi) Tensile strength 4462 4099
4344 (psi) Elongation, % 675 591 600 Max.Tan Delta 0.189 .237 .184
@ 60 C. (Strain Sweep) Crack Growth 0.8 5.0 5.8 Rate (cm/per
million cycles)
Additional Examples and Comparisons
[0125] Highly preferred elastomer composites in accordance with the
present invention were produced in accordance with the method and
apparatus disclosed above. In particular, novel masterbatch
compositions were formed of natural rubber latex and carbon black
filler, having significantly better macro-dispersion levels and/or
natural rubber molecular weight than heretofore found in known
compositions formed of the same or similar staring materials. FIG.
8 shows the surface area and structure of various carbon black
fillers used in these preferred masterbatch compositions,
specifically, the CTAB surface area expressed as square meters per
gram of carbon black per ASTM D3765-85 and dibutyl phthalate
absorption (DBPA) value expressed as cubic centimeters of DBP per
hundred grams carbon black per ASTM D2414 are shown. FIG. 8 is seen
to be divided into three different regions of carbon blacks. Region
I contains carbon blacks having lower structure and higher surface
area, being those most difficult to disperse in natural rubber and
other elastomers using traditional dry mixing techniques. Hence,
carbon blacks of Region I are not used commercially as widely as
other carbon blacks, Masterbatch and cured elastomeric compositions
made with Region I carbon blacks using traditional dry mixing
techniques have poorer macro-dispersion and typically lower
MW.sub.sol. The carbon blacks of Region II have higher structure
than those of Region I. Typically, they achieve reasonably good
dispersion in natural rubber for vehicle tire products and the like
if subjected to such extended dry mixing that the MW.sub.sol of the
natural rubber is significantly degraded. The carbon blacks of
Region III of FIG. 8 have lower surface area relative their
structure. Accordingly they have been used with acceptable
dispersion in natural rubber via dry mixing, but again, with
undesirable degradation of MW.sub.sol. The dispersion of carbon
blacks of all three regions of FIG. 8, specifically,
macro-dispersion, is significantly improved in the elastomer
composites disclosed here, and can be achieved with significantly
higher MW.sub.sol of the natural rubber in accordance with
preferred embodiments.
Control Samples 1-443
[0126] Control samples of masterbatch were prepared by dry mixing
in accordance with the following procedures, for purposes of
comparison to elastomer composites of the present invention.
[0127] 1. Mastication of Natural Rubber
[0128] In order to produce dry masterbatches with a wide range of
molecular weight, commercial natural rubber (RSS1, SMR CV, and SMR
10) bales were pre-masticated in a BR banbury mixer using the
following conditions (fill factor: 0.75):
11TABLE 11 Natural Rubber Mastication Conditions Sample Rotor Speed
Cooling Mastiation Code Mastication (rpm) Water time (min.) M1 No
M2 Yes 77 On 4 M3 Yes 118 On 6 M4 Yes 118 On 10
[0129] 2. Mixing Carbon Black with Pre-Masticated Natural
Rubber
[0130] In order to prepare natural rubber dry masterbatches with
different levels of macro-dispersion quality, the following mixing
procedures were used in a BR Banbury mixer. The fill factor was
0.70. The masterbatch ingredients and mixing procedures are
described as follows in Table 12.
12TABLE 12 Natural Rubber Dry Masterbatch Formulation phr (Parts
per hundred parts of rubber by Ingredient weight) Natural Rubber
100 Carbon Black See Tables Below Oil See Tables Below Santofex
(antioxidant) 0.4 TNPP (antioxidant) 0.3 Mixing Procedures: 0
minute: Add pre-masticated natural rubber (77 rpm, 45 C.) 1 minute:
Add black, oil and antioxidants
[0131] Different levels of nacrodispersion were produced by dry
mixing samples of M1 through M4 premasticated natural rubber for
different mixing times, as shown in Table 13, below. For example,
sample code M2D1 in Table 13 indicates a control sample of
premasticated natural rubber M2 (see Table 11, above) mixed for 10
minutes in accordance with the formulation of Table 12.
13TABLE 13 Mixing Times Dry NR Masterbatch Sample Code
Pre-Masticated NR Mixing Time M1D4 M1 4 M1D3 M1 6 M1D2 M1 8 M1D1 M1
10 M2D4 M2 4 M2D3 M2 6 M2D2 M2 8 M2D1 M2 10 M3D4 M3 4 M3D3 M3 6
M3D2 M3 8 M3D1 M3 10 M4D4 M4 4 M4D3 M4 6 M4D2 M4 8 M4D1 M4 10
[0132] 3. Final mixing of Natural Rubber Masterbatch Control
Samples
[0133] To evaluate compound performance, additional ingredients
were added to the dry masticated natural rubber masterbatch control
samples of Table 13 in accordance with the formulation shown in
Table 14.
14TABLE 14 Additional Ingredients for Final Mixing Ingredient
Amount (phr) Azo 66 (zinc oxide) 4.0 Hystere 5016 (stearic acid)
2.0 Santoflex 13 (antioxidant) 2.0 Sunproof Improved (wax) 2.0
Wingstay 100 (antioxidant) 1.0 Santocure NS (sulfur accelerator) 18
Sulfur 1.0
[0134] The compounds were cured in accordance with standard cure
techniques at 150.degree. C. until at least substantially
completely cured, typically between 10 and 30 minutes. In that
regard, the same or substantially the same final mixing procedures,
including the formulation given above in Table 14, were used for
all control samples, as well as all samples of elastomer composites
of the invention prepared in the manner described below (see
"Preferred Embodiments Examples) which were cured and tested for
compound properties and performance characteristics.
[0135] The following tables 15-23 set forth the sol molecular
weight MW.sub.sol and macro-dispersion D (%) of control samples 1
through 443. The samples are grouped in the tables according to
choice of carbon black. Within a given table, the samples are
grouped by choice of natural rubber and by carbon black loading and
oil loading. The table headings show this information in accordance
with standard nomenclature. Thus, for example, the heading for
Table 15 "N330/55 phr/0"" indicates 55 phr N330 carbon black with
no oil. The table sub-headings show the choice of natural rubber.
Specifically, control samples 1 through 450 are seen to be made
from standard grade natural rubber RSS1, SMRCV and SMR10. Technical
description of these natural rubbers is widely available, such as
in Rubber World Magazine's Blue Book published by Lippincott and
Peto, Inc. (Akron, Ohio, USA). The molecular weight MW.sub.sol of
the natural rubber prior to any premastication (M1) and after the
various amounts of premastication (M2-M4) also are shown below in
Tables 15-23.
15 TABLE 15 N330/55 phr/0 RSS1 SMRCV Sample Mw.sub.sol Sample
Mw.sub.sol Code No. (K) D (%) No. (K) D (%) M1 1300 971 M2 932 725
M3 664 596 M4 485 482 M1D1 1 465 4.24 17 426 4.35 M1D2 2 571 3.70
18 467 3.89 M1D3 3 706 4.79 19 486 4.86 M1D4 4 770 4.52 20 535 4.78
M2D1 5 445 3.66 21 380 2.44 M2D2 6 490 2.68 22 398 3.71 M2D3 7 512
3.68 23 433 4.30 M2D4 8 581 3.93 24 498 5.81 M3D1 9 373 1.33 25 342
3.79 M3D2 10 402 2.50 26 358 4.35 M3D3 11 407 2.98 27 371 5.55 M3D4
12 452 3.35 28 408 5.01 M4D1 13 311 3.63 29 311 3.66 M4D2 14 337
3.40 30 325 5.31 M4D3 15 362 5.03 31 344 5.91 M4D4 16 382 5.23 32
369 5.67
[0136]
16 TABLE 16 Black Pearl 800/55 phr/0 RSS1 SMRCV Sample Mw.sub.sol
Sample Mw.sub.sol Code No. (K) D (%) No. (K) D (%) M1 1041 869 M2
786 662 M3 663 491 M4 527 420 M1D1 113 507 12.20 129 418 5.15 M1D2
114 551 15.10 130 482 4.94 M1D3 115 700 10.20 131 515 6.93 M1D4 116
786 5.72 132 583 8.74 M2D1 117 420 5.65 133 403 2.60 M2D2 118 441
6.50 134 438 2.74 M2D3 119 549 7.70 135 434 2.83 M2D4 120 606 5.88
136 530 3.88 M3D1 121 387 3.26 137 366 2.38 M3D2 122 409 2.98 138
378 2.83 M3D3 123 456 3.61 139 399 3.04 M3D4 124 483 4.61 140 431
2.39 M4D1 125 339 2.13 141 311 2.22 M4D2 126 367 2.23 142 332 2.27
M4D3 127 360 2.60 143 344 2.27 M4D4 128 403 1.96 144 390 2.73
[0137]
17 TABLE 17 N351/33 phr/20 phr RSS1 Sample Mw.sub.sol Code No. (K)
D (%) M1 1300 M2 803 M3 601 M1D1 401 854 2.08 M1D2 402 969 3.41
M1D3 403 1040 3.68 M1D4 404 1130 4.91 M2D1 405 648 1.15 M2D2 406
668 2.16 M2D3 407 675 2.98 M2D4 408 721 4.70 M3D1 409 532 1.10 M3D2
410 537 2.17 M3D3 411 535 2.45 M3D4 412 558 4.06
[0138]
18 TABLE 18A Regal 250/55 phr/0 RSS1 SMRCV Sample Mw.sub.sol Sample
Mw.sub.sol Code No. (K) D (%) No. (K) D (%) M1 1332 1023 M2 896 748
M3 603 581 M4 408 504 M1D1 33 585 6.95 49 609 1.93 M1D2 34 669 5.03
50 634 3.29 M1D3 35 759 10.5 51 681 2.21 M1D4 36 896 14.1 52 702
4.09 M2D1 37 580 2.71 53 539 2.14 M2D2 38 602 2.61 54 569 2.72 M2D3
39 631 3.61 55 587 4.75 M2D4 40 667 5.43 56 595 6.25 M3D1 41 457
1.53 57 466 2.88 M3D2 42 476 2.09 58 449 3.19 M3D3 43 493 2.32 59
464 4.53 M3D4 44 495 3.54 60 500 5.89 M4D1 45 372 1.53 61 423 2.89
M4D2 46 382 2.09 62 433 3.42 M4D3 47 381 2.32 63 437 4.39 M4D4 48
403 3.54 64 447 4.73
[0139]
19 TABLE 18B Regal 250/65/0 Regal 250/75/0 Regal 250/65/10 RSS1
RSS1 RSS1 Sample Mw.sub.sol Sample Mw.sub.sol Sample Mw.sub.sol
Code No. (K) D (%) No. (K) D (%) No. (K) D (%) M1 1138 1138 1138 M2
901 901 901 M3 660 660 660 M4 483 483 483 M1D1 65 570 1.50 81 539
2.87 97 661 1.89 M1D2 66 622 3.25 82 624 4.50 98 702 2.69 M1D3 67
707 7.50 83 685 4.17 99 741 3.14 M1D4 68 788 4.77 84 763 14.35 100
822 5.24 M2D1 69 534 1.62 85 484 4.32 101 593 0.91 M2D2 70 548 4.19
86 512 2.96 102 572 3.48 M2D3 71 585 4.31 87 557 4.71 103 642 4.23
M2D4 72 621 6.21 88 605 4.85 104 664 5.35 M3D1 73 459 3.64 89 429
2.27 105 507 2.65 M3D2 74 469 5.79 90 446 2.68 106 544 2.96 M3D3 75
511 5.30 91 466 3.46 107 535 3.69 M3D4 76 541 9.13 92 491 6.22 108
524 3.27 M4D1 77 380 2.34 93 368 2.11 109 416 1.85 M4D2 78 392 2.86
94 372 3.13 110 413 3.18 M4D3 79 399 4.59 95 375 2.92 111 418 6.96
M4D4 80 395 4.57 96 388 2.92 112 441 6.46
[0140]
20 TABLE 19 N326/55 phr/0 RSS1 SMRCV Sample Mw.sub.sol Sample
Mw.sub.sol Code No. (K) D (%) No. (K) D (%) M1 1200 1060 M2 1030
934 M3 724 777 M4 635 644 M1D1 145 550 3.49 161 644 1.15 M1D2 146
636 3.54 162 661 1.32 M1D3 147 650 5.89 163 697 1.35 M1D4 148 724
4.79 164 732 2.01 M2D1 149 517 3.16 165 590 1.50 M2D2 150 572 2.41
166 621 1.56 M2D3 151 613 3.11 167 641 2.22 M2D4 152 696 4.37 168
676 2.31 M3D1 153 489 2.78 169 551 1.22 M3D2 154 521 1.93 170 550
1.62 M3D3 155 504 3.14 171 563 2.06 M3D4 156 538 2.81 172 578 2.68
M4D1 157 415 1.74 173 487 1.96 M4D2 158 447 2.17 174 495 2.22 M4D3
159 466 3.13 175 505 2.99 M4D4 160 469 2.93 176 526 3.37
[0141]
21 TABLE 20 N110/55 phr/0 RSS1 SMRCV Sample Mw.sub.sol Sample
Mw.sub.sol Code No. (K) D (%) No. (K) D (%) M1 937 730 M2 764 653
M3 569 541 M4 449 463 M1D1 389 360 1.24 385 334 1.28 M1D2 370 426
2.50 386 339 1.60 M1D3 371 490 2.69 387 372 1.42 M1D4 372 618 4.68
388 413 2.80 M2D1 373 340 0.69 389 309 0.72 M2D2 374 356 0.85 390
314 1.17 M2D3 375 395 0.90 391 342 1.27 M2D4 376 433 1.17 392 380
2.94 M3D1 377 295 0.81 393 271 0.94 M3D2 378 313 1.27 394 292 0.93
M3D3 379 333 1.20 395 314 1.43 M3D4 380 353 1.35 396 351 1.77 M4D1
381 255 1.12 397 260 0.74 M4D2 382 269 1.14 398 267 0.93 M4D3 383
287 1.30 399 284 1.49 M4D4 384 316 1.67 400 297 1.83
[0142]
22 TABLE 21(A) S6740/55 phr/0 RSS1 Sample Mw.sub.sol Code No. (K) D
(%) M1 1080 M2 837 M3 724 M4 532 M1D1 412 515 1.24 M1D2 413 556
1.32 M1D3 414 633 1.41 M1D4 415 732 1.43 M2D1 416 433 0.86 M2D2 417
451 0.90 M2D3 418 495 1.53 M2D4 419 542 2.15 M3D1 420 405 0.25 M3D2
421 418 0.50 M3D3 422 447 0.75 M3D4 423 469 0.73 M4D1 424 371 0.21
M4D2 425 387 0.42 M4D3 426 382 0.30 M4D4 427 396 0.56
[0143]
23 TABLE 21(B) S6740/55 phr/0 SMRCV Sample Mw.sub.sol Code No. (K)
D (%) M1 876 M2 754 M3 574 M4 444 M1D1 428 433 0.25 M1D2 429 441
0.36 M1D3 430 467 0.34 M1D4 431 540 0.84 M2D1 432 399 0.35 M2D2 433
399 0.41 M2D3 434 422 0.62 M2D4 435 469 0.44 M3D1 438 340 0.44 M3D2
437 363 0.81 M3D3 438 377 0.89 M3D4 439 403 0.86 M4D1 440 363 0.65
M4D2 441 328 1.05 M4D3 442 342 1.52 M4D4 443 360 1.99
[0144]
24 TABLE 22(A) Regal 660/55 phr/0 RSS1 SMRCV SMR10 Sample
Mw.sub.sol Sample Mw.sub.sol Sample Mw.sub.sol Code No. (K) D (%)
No. (K) D (%) No. (K) D (%) M1 1110 836 746 M2 844 709 632 M3 609
584 492 M4 522 513 416 M1D1 177 674 8.35 193 564 1.87 209 501 9.54
M1D2 178 792 7.89 194 611 2.50 210 572 6.68 M1D3 179 891 8.53 195
708 3.08 211 681 7.37 M1D4 180 676 7.46 196 671 2.31 212 594 7.18
M2D1 181 598 8.56 197 520 5.28 213 463 2.82 M2D2 182 602 3.89 198
558 4.85 214 483 4.57 M2D3 153 697 6.40 199 603 2.88 215 565 3.92
M2D4 184 659 5.71 200 541 4.25 216 550 5.68 M3D1 185 473 2.03 201
486 2.79 217 395 2.13 M3D2 186 506 1.66 202 482 2.76 218 393 1.98
M3D3 187 562 1.94 203 504 3.54 219 443 2.49 M3D4 188 559 4.33 204
526 2.41 220 449 1.90 M4D1 189 401 2.18 205 415 3.16 221 335 1.49
M4D2 190 426 1.72 206 418 2.92 222 345 1.71 M4D3 191 466 1.48 207
446 2.80 223 363 1.78 M4D4 192 449 3.57 208 465 3.13 224 374
2.35
[0145]
25 TABLE 22(B) Regal 660/45/0 Regal 660/65/0 Regal 660/65/10 RSS1
RSS1 RSS1 Sample Mw.sub.sol Sample Mw.sub.sol Sample Mw.sub.sol
Code No. (K) D (%) No. (K) D (%) No. (K) D (%) M1 1245 1245 1245 M2
876 876 876 M3 625 625 625 M4 482 482 482 M1D1 225 646 3.45 241 563
14.55 257 639 1.63 M1D2 226 697 3.04 242 638 14.09 258 699 3.55
M1D3 227 762 7.70 243 691 13.64 259 814 5.44 M1D4 228 830 6.75 244
790 11.26 260 764 11.25 M2D1 229 574 4.79 245 469 5.88 261 572 2.77
M2D2 230 589 3.02 246 507 7.31 262 580 4.39 M2D3 231 636 6.41 247
558 9.72 263 610 5.51 M2D4 232 675 6.55 248 543 10.59 264 638 7.29
M3D1 233 471 2.66 249 420 5.48 265 474 4.10 M3D2 234 481 5.17 250
426 6.97 266 485 5.72 M3D3 235 510 7.78 251 468 8.81 267 502 6.24
M3D4 236 518 7.89 252 471 9.55 268 495 7.13 M4D1 237 388 3.20 253
335 5.19 269 390 5.02 M4D2 238 392 5.65 254 344 6.06 270 365 5.88
M4D3 239 397 5.14 255 344 5.59 271 410 7.45 M4D4 240 403 7.54 256
361 8.54 272 388 7.59
[0146]
26 TABLE 23(A) N234/55phr/0 RSS1 SMRCV SMR10 Sample Mw.sub.sol
Sample Mw.sub.sol Sample Mw.sub.sol Code No. (K) D (%) No. (K) D
(%) No. (K) D (%) M1 1060 845 743 M2 811 712 621 M3 595 577 445 M4
466 477 388 M1D1 273 350 1.88 289 312 0.61 305 325 0.78 M1D2 274
476 3.40 290 317 0.64 306 363 1.66 M1D3 275 459 2.70 291 361 1.03
307 400 1.89 M1D4 276 665 2.70 292 419 1.56 308 459 1.73 M2D1 277
323 0.40 293 304 0.76 309 294 0.54 M2D2 278 371 0.73 294 306 0.72
310 321 1.24 M2D3 279 398 0.74 295 318 0.74 311 354 1.28 M2D4 280
464 1.42 296 357 1.30 312 363 1.39 M3D1 281 278 0.47 297 260 0.53
313 260 0.69 M3D2 282 304 0.83 298 272 0.65 314 268 0.48 M3D3 283
323 0.82 299 295 0.58 315 289 1.38 M3D4 284 360 1.06 300 302 1.14
315 303 0.78 M4D1 285 251 0.61 301 244 0.53 317 236 1.00 M4D2 286
266 0.51 302 253 0.81 318 239 0.77 M4D3 287 273 0.64 303 266 0.62
319 257 0.72 M4D4 288 282 0.53 304 296 0.88 320 268 1.30
[0147]
27 TABLE 23(B) N234/45/0 N234/65/0 N234/65/10 RSS1 RSS1 RSS1 Sample
Mw.sub.sol Sample Mw.sub.sol Sample Mw.sub.sol Code No. (K) D (%)
No. (K) D (%) No. (K) D (%) M1 1185 1185 1185 M2 828 828 828 M3 623
623 623 M4 462 462 462 M1D1 321 507 7.33 337 336 3.44 353 395 5.51
M1D2 322 598 8.15 338 458 5.09 354 478 7.68 M1D3 323 731 8.97 339
479 8.17 355 555 9.46 M1D4 324 772 12.02 340 706 9.90 356 637 8.39
M2D1 325 486 3.48 341 255 3.22 357 295 0.58 M2D2 326 479 5.44 342
288 3.34 358 352 1.23 M2D3 327 527 5.51 343 295 4.65 359 394 1.35
M2D4 328 566 7.70 344 393 5.45 360 449 2.37 M3D1 329 419 0.88 345
237 1.50 361 292 0.86 M3D2 330 423 1.24 346 252 1.78 362 286 1.14
M3D3 331 431 2.55 347 270 2.88 363 313 2.19 M3D4 332 458 4.03 348
304 3.92 364 340 2.51 M4D1 333 341 0.62 349 226 1.18 365 265 0.83
M4D2 334 338 1.13 350 214 1.81 366 273 0.99 M4D3 335 319 1.37 351
233 2.97 367 291 1.39 M4D4 336 354 2.06 352 258 3.83 368 307
2.41
Preferred Embodiment Examples
[0148] Additional samples of elastomer composites in accordance
with the present invention were prepared. Specifically, a series of
natural rubber elastomer composites no. 1-32 in accordance with the
present invention was produced using apparatus and procedures
generally in accordance with those of Example A above. The
elastomer composites comprised natural rubber field latex from
Malaysia with the properties shown in Table 24 below. The elastomer
composites each further comprised carbon black with morphological
properties (structure and surface area) of Regions I, II or III in
FIG. 8. Specifically, the following carbon blacks were used:
Regal.RTM. 660, N234, N326, N110, Regal.RTM. 250, N330, Black
Pearl.RTM. 800, Sterling.RTM. 6740 and N351. The carbon black
loadings ranged from 30 to 75 phr, and extender oil loadings were
in an amount from 0 to 20 phr. The production details for elastomer
composite sample nos. 1-32 are shown below in Table 25.
[0149] As noted above, the apparatus and procedures used to prepare
elastomer composites no. 1-32 were generally in accordance with
those of Example A, including the masterbatch formulation additives
shown in Table 2. A more detailed description of the apparatus and
procedures used for elastomer composites no. 1-32 is set forth
below.
[0150] 1. Apparatus
[0151] Invention samples no. 1-32 were prepared using masterbatch
production apparatus substantially in accordance with the invention
apparatus described above with reference to FIGS. 1, 4 and 7. The
diameter of the slurry nozzle tip (see item 167 in FIG. 7) and the
length of the land (see item 168 in FIG. 7) are given in Table 25
for each of samples no. 1-32. The coagulum zone of the apparatus
had four zones of progressively larger diameter from the mixing
zone to the discharge end. The diameter and axial length of each of
the four zones (the first zone being partly within the mix-head and
partly within the extender sealed thereto) are set forth in Table
25. There were axially short, faired interconnections between the
zones.
[0152] 2. Carbon Black Slurry Preparation
[0153] Bags of carbon black were mixed with deionized water in a
carbon black slurry tank equipped with an agitator. The agitator
broke the pellets into fragments to form a crude carbon black
slurry. The carbon black concentration (as weight percent) in the
carbon black slurry for each of the sample is given in Table 25.
During operation, this slurry was continually pumped by an air
diaphragm pump to a grinder for initial dispersion. The slurry was
then fed via an air diaphragm pump to a colloid mill which then fed
into a progressing cavity pump to a homogenizer, specifically,
Microfluidizer Model M210 from Microfluidics International
Corporation. The microfluidizer produced a finely ground slurry.
The slurry flow rate from the microfluidizer to the mixing zone was
set by the microfluidizer pressure, the microfluidizer acting as a
high-pressure positive displacement pump. Slurry flow rate was
monitored with a Micromotion.RTM. mass flow meter. The pressure at
which the carbon black slurry was fed to the homogenizer and the
homogenizer output pressure (all pressures are psig) are set forth
for each sample in Table 25. From the homogenizer the carbon black
slurry was fed to an accumulator to reduce any fluctuation in
slurry pressure at the slurry nozzle tip in the mixing zone. The
slurry nozzle tip pressure and flow rate at which the slurry was
fed to the mixing zone for each sample are given in Table 25.
[0154] 3. Latex Delivery
[0155] The latex was charged to a 55 gallon feed drum. Antioxidant
emulsion was then added to the latex and mixed in prior to
charging. Antioxidants were added consisting of tris nonyl phenyl
phosphite (TNPP) and Santoflex.RTM. 134 (alkylaryl p-phenylene
diamine mixture) in the amounts shown in Table 25. Each of the
antioxidants was prepared as a 40 wt. % emulsion using 4 parts
potassium oleate per 100 parts antioxidant along with potassium
hydroxide to adjust the emulsion to a pH of approximately 10.
Extender oil, if any, was added in the amount shown in Table 25. A
peristaltic pump was used to move the latex from the feed drum to
the mixing zone of the coagulum reactor. The latex flow rate and
velocity are shown in Table 25. Latex flow was automatically
metered with a Endress+Hauser mass flow meter. The desired carbon
black loading was obtained by maintaining proper ratio of the latex
feed rate to the carbon black slurry feed rate.
[0156] 4. Carbon Black and Latex Mixing
[0157] The carbon black slurry and latex were mixed by entraining
the latex into the carbon black slurry. During entrainment, the
carbon black was intimately mixed into the latex and the mixture
coagulated. Soft, wet spongy "worms" of coagulum exited the
coagulum reactor.
[0158] 5. Dewatering
[0159] The water content of the wet crumb discharged from the
coagulum reactor is shown in Table 25. The wet crumb was dewatered
with a dewatering extruder (The French Oil Mill Machinery Company;
31/2 in. diameter). In the extruder, the wet crumb was compressed
and water squeezed form the crumb and through a slotted barrel of
the extruder. The final crumb moisture content is shown in Table 25
for each of the invention samples.
[0160] 5. Drying and Cooling
[0161] The dewatered crumb dropped into a second extruder where it
was again compressed and heated. Water was flashed off upon
expulsion of the crumb through the die plate of the extruder.
Product exit temperature and moisture content are shown in Table
25. The hot, dry crumb was rapidly cooled (approximately 20
seconds) to about 100.degree. F. by a forced air vibrating
conveyor.
28TABLE 24 Natural Rubber Latex Properties Volatile % Dry % Total
Nitrogen Fatty Latex Type Source Additives Rubber Solids % Ash ppm
Acid Concentrate TITI Latex 0.35% NH.sub.3 60 62.0 0.15 0.29 0.022
SDN.BHD. ZnO, TMTD 0.1% HHS Field Latex RRIM.sup.a, 9/94 0.15%
HNS.sup.c 28.4 34.2 0.38 0.366 0.052 0.3% NH3, ZnO, TMTD.sup.b
.sup.aRRIM is the Rubber Research Institute of Malaysia
.sup.bZnO/TMTD: used for biological preservation, typical 0.025% of
1:1 mixture .sup.cHNS: hydroylamine neutral sulfate, Mooney
viscosity stabilizer
[0162]
29TABLE 25 Invention Sample Production Details Cabot Elastomer
Composite Slurry Nozzle Tip MicroFluidizer Invention Carbon Black
Oil loading Land length Inlet pressure Outlet pressure Sample No.
Latex type Type Loading (phr) (phr) Dia. (in) (in) (psi) (psi) 1
field latex N330 55 0 0.025 0.5 190 3000 2 field latex N330 55 0
0.039 1 300 0 3 field latex N330 55 0 0.039 1 300 0 4 field latex
REGAL 250 55 0 0.025 0.5 100 3500 5 field latex REGAL 250 65 0
0.025 0.5 300 10000 6 field latex REGAL 250 75 0 0.025 0.5 200
13000 7 field latex REGAL 250 65 10 0.025 0.5 250 12000 8 field
latex BLACK PEARL 800 55 0 0.025 0.5 200 4000 9 field latex N326 55
0 0.025 1 250 3000 10 field latex REGAL 660 55 0 0.025 1 -- -- 11
field latex REGAL 660 45 0 0.025 0.5 200 12500 12 field latex REGAL
660 65 0 0.025 0.5 260 15000 13 field latex REGAL 660 65 10 0.025
0.5 200 12000 14 field latex N234 55 0 0.025 1 180 5500 15 field
latex N234 55 0 0.025 0.5 -- 14500 16 field latex N234 55 0 0.025
0.5 -- 14500 17 field latex N234 55 0 0.025 0.5 -- 14500 18 field
latex N234 45 0 0.025 0.5 200 13000 19 field latex N234 65 0 0.025
0.5 220 13000 20 field latex N234 65 10 0.025 0.5 300 14500 21
field latex N110 55 0 0.025 1 120 4500 22 latex concentrate N351 33
20 0.025 0.5 250 12500 23 field latex STERLING 6740 55 0 0.025 0.5
250 12000 24 field latex N234 48 5 0.023 0.5 250 11000 25 field
latex N234 53 5 0.023 0.5 250 11000 26 field latex N234 58 5 0.023
0.5 250 11000 27 field latex N234 63 5 0.023 0.5 250 11000 28 field
latex N234 68 5 0.023 0.5 250 11000 29 latex co ncentrate N234 49 5
0.023 0.5 -- -- 30 latex concentrate N234 54 5 0.023 0.5 -- 11000
31 latex concentrate N234 63 5 0.023 0.5 -- 11000 32 latex
concentrate N234 65 5 0.023 0.5 -- 11000 Coagulum Zone CB Slurry
Invention 1st portion 2nd portion 3rd portion 4th portion CB conc.
Sample No. Dia. (ln) Length (ln) Dia. (ln) Length (ln) Dia. (ln)
Length (ln) Dia. (ln) Length (ln) (% wt) 1 0.19 3.0 0.27 1.6 0.38
2.3 0.53 3.2 15.2 2 0.19 1.1 0.27 1.6 0.38 2.3 0.53 3.2 14.9 3 0.19
1.1 0.27 1.6 0.38 2.3 0.53 3.2 14.9 4 0.19 3.0 0.27 1.6 0.38 2.3
0.53 3.2 19.0 5 0.19 3.0 0.27 1.6 0.38 2.3 0.53 3.2 21.0 6 0.19 3.0
0.27 1.6 0.38 2.3 0.53 3.2 21.0 7 0.19 3.0 0.27 1.6 0.38 2.3 0.53
3.2 21.0 8 0.19 3.0 0.27 1.6 0.38 2.3 0.53 3.2 15.0 9 0.19 1.1 0.27
1.6 0.38 2.3 0.53 3.2 14.8 10 0.19 1.1 0.27 1.6 0.38 2.3 0.53 3.2
14.9 11 0.19 3.0 0.27 1.6 0.38 2.3 0.53 3.2 15.2 12 0.19 3.0 0.27
1.6 0.38 2.3 0.53 3.2 15.2 13 0.19 3.0 0.27 1.6 0.38 2.3 0.53 3.2
15.2 14 0.19 1.1 0.27 1.6 0.38 2.3 0.53 3.2 14.8 15 0.19 3.0 0.27
1.6 0.38 2.3 0.53 3.2 13.7 16 0.19 3.0 0.27 1.6 0.38 2.3 0.53 3.2
13.7 17 0.19 3.0 0.27 1.6 0.38 2.3 0.53 3.2 13.7 18 0.19 3.0 0.27
1.6 0.38 2.3 0.53 3.2 14.6 19 0.19 3.0 0.27 1.6 0.38 2.3 0.53 3.2
14.6 20 0.19 3.0 0.27 1.6 0.38 2.3 0.53 3.2 14.6 21 0.19 1.1 0.27
1.6 0.38 2.3 0.53 3.2 11.6 22 0.19 3.0 0.27 1.6 0.38 2.3 0.53 3.2
15.0 23 0.19 3.0 0.27 1.6 0.38 2.3 0.53 3.2 14.7 24 0.19 3.0 0.27
1.6 0.38 2.3 0.53 3.2 13.5 25 0.19 3.0 0.27 1.6 0.38 2.3 0.53 3.2
13.5 26 0.19 3.0 0.27 1.6 0.38 2.3 0.53 3.2 13.5 27 0.19 3.0 0.27
1.6 0.38 2.3 0.53 3.2 13.5 28 0.19 3.0 0.27 1.6 0.38 2.3 0.53 3.2
13.5 29 0.19 3.0 0.27 1.6 0.38 2.3 0.53 3.2 12.8 30 0.19 3.0 0.27
1.6 0.38 2.3 0.53 3.2 12.8 31 0.19 3.0 0.27 1.6 0.38 2.3 0.53 3.2
12.8 32 0.19 3.0 0.27 1.6 0.38 2.3 0.53 3.2 12.8 Slurry Nozzle
Mixing Zone Invention Tip Pressure Slurry flow rate Slurry velocity
Antioxidant Latex flow rate Latex velocity Sample No. (psi)
(lb/min) (ft/sec) TNPP (phr) Santoflex(phr) (lbs/min) (ft/sec) 1
1400 4.6 336 0.3 0.4 4.7 6.8 2 425 8.2 247 0.3 0.4 8.9 13.2 3 425
8.2 247 0.3 0.4 8.9 13.2 4 1500 4.8 344 0.3 0.4 6.7 9.7 5 1500 5.2
370 0.3 0.4 6.6 9.8 6 1575 5.2 370 0.3 0.4 5.9 8.5 7 1500 5.2 370
0.3 0.4 6.9 10.0 8 1800 5.2 380 0.3 0.4 4.9 7.1 9 600 4.2 308 0.3
0.4 4.0 5.8 10 -- 4.0 293 0.3 0.4 3.6 5.2 11 1500 5.1 373 0.3 0.4
7.0 10.1 12 1300 4.8 351 0.3 0.4 4.6 6.7 13 1375 4.9 358 0.3 0.4
4.8 6.9 14 900 5.3 366 0.3 0.4 4.8 6.9 15 1400 5.7 420 0.3 0.4 5.4
7.8 16 1400 5.7 420 0.3 0.4 5.4 7.6 17 1400 5.7 420 0.3 0.4 5.4 7.8
18 1600 5.2 381 0.3 0.4 6.5 9.4 19 1650 5.3 388 0.3 0.4 4.5 6.5 20
1625 5.3 388 0.3 0.4 4.6 6.7 21 900 5.3 394 0.3 0.4 4.1 5.9 22 1550
5.1 373 0.3 0.4 5.1 7.6 23 1550 5.2 381 0.3 0.4 5.7 8.3 24 2270 5.1
444 0.3 0.4 6.1 8.8 25 2250 5.1 444 0.3 0.4 5.5 7.9 26 2270 5.1 444
0.3 0.4 5.0 7.2 27 2280 5.1 444 0.3 0.4 4.6 6.6 28 -- 5.1 444 0.3
0.4 4.2 6.1 29 2350 5.3 463 0.3 0.4 2.6 3.8 30 2360 5.3 463 0.3 0.4
2.3 3.4 31 2350 5.3 463 0.3 0.4 2.1 3.1 32 2420 5.3 463 0.3 0.4 2.0
3.0 Dewatering Drying and Cooling Invention Initial crumb moisture
Final crumb moisture Product temperature Product moisture Sample
No. (%) (%) (.degree. F.) (%) 1 77.6 6.5 312 0.3 2 76.7 -- 450 0.2
3 78.7 7.8 400 0.2 4 74.9 -- 350 0.3 5 76.2 7.9 310 0.2 6 76.4 11.4
-- 0.2 7 75.6 8.8 335 0.3 8 77.7 6.5 310 0.2 9 77.9 8.9 345 0.2 10
77.8 -- -- 0.4 11 78.7 9.7 285 0.5 12 79.7 -- 335 0.2 13 79.1 -- --
0.9 14 77.9 8.4 330 0.1 15 79.2 -- oven dried -- 16 79.2 10.3 oven
dried -- 17 79.2 11.2 oven dried -- 18 79.0 15.0 370 0.4 19 80.0
3.6 325 0.3 20 79.5 9.4 345 0.5 21 80.5 9.5 350 0.2 22 65.1 9.1 280
0.3 23 78.1 6 330 0.8 24 77.4 -- 380 0.3 25 77.8 -- 390 0.4 26 78.1
-- 400 0.7 27 78.4 -- 410 0.4 28 78.7 -- 420 1.1 29 71.2 -- 400 0.6
30 72.3 -- 420 0.4 31 73.3 -- 400-450 0.9 32 74.1 -- 400-450
0.2
[0163] It should be noted that samples 2 and 3 were produced with
approximately no outlet pressure at the Microfluidizer outlet,
etc., to determine macro-dispersion under adverse process
conditions.
[0164] The excellent carbon black dispersion in the resultant
masterbatches is demonstrated by their macro-dispersion quality and
molecular weight of the sol portion MW.sub.sol. Table 26 below
shows the MW.sub.sol and macro-dispersion values for invention
samples 1-32, along with the carbon black and oil (if any) used in
each of the samples. The carbon black loading and oil loading are
shown as phr values in Table 26.
30TABLE 26 Sol Molecular Weight and Undispersed Area Invention
Samples Invention Sample No. CB/Loading/Oil Mw.sub.sol (K) D (%) 1
N330/55/0 305 0.26 2 N330/55/0 726 0.54 3 N330/55/0 544 0.40 4
R250/55/0 876 0.08 5 R250/55/0 670 0.16 6 R250/75/0 655 0.03 7
R250/65/10 519 0.02 8 BP800/55/D 394 0.14 9 N326/55/0 666 0.20 10
R660/55/0 678 0.12 11 R660/45/0 733 0.05 12 R660/65/0 568 0.04 13
R660/65/0 607 0.02 14 N234/55/0 433 0.15 15 N234/55/0 1000 0.10 16
N234/55/0 500 0.15 17 N234/55/0 550 0.10 18 N234/45/0 495 0.17 19
N234/65/0 359 0.20 20 N234/65/10 350 0.11 21 N110/55/0 612 0.17 22
N351/33/20 800 0.10 23 S6740/55/0 630 0.10 24 N234/48/5 569 0.05 25
N234/53/5 485 0.12 26 N234/58/5 447 0.12 27 N234/63/5 403 0.13 28
N234/68/5 378 0.16 29 N234/49/5 618 0.12 30 N234/54/5 482 0.16 31
N234/63/5 390 0.17 32 N234/65/5 325 0.20
[0165] The results for all invention samples having carbon black
loading of 55 phr are shown in the semi-log slot of FIG. 9 along
with macro-dispersion and MW.sub.sol values for a corresponding
series of the above described natural rubber control samples
produced by dry mixing techniques. At least one data point for an
invention sample comprising 55 phr loading of each carbon black is
shown in FIG. 9, along with all of the control samples having
carbon black loading of 55 phr. (Control samples 401 to 412, also
shown in FIG. 9, used 33 phr N351 carbon black and 20 parts
extender oil.) It can be seen in Table 26 and in FIG. 9 that the
invention samples have excellent macro-dispersion. Specifically,
the invention samples have D (%) values generally below 0.2%, even
at MW.sub.sol values above 0.85.times.10.sup.6 whereas the control
samples never achieve such excellent macro-dispersion at any
MW.sub.sol. Thus, the data shown in FIG. 9 clearly reveals that the
macro-dispersion quality of the novel elastomer composites over a
wide range of MW.sub.sol values is significantly superior to that
achievable using comparable ingredients in prior-known dry mixing
methods. The symbols used for the various data points shown in FIG.
9 and those used in subsequently discussed FIGS. 10-25 are
explained in the legends below.
FIGURE CAPTIOPNS
[0166] FIG. 9 Dispersion Quality and MW Sol of NR Masterbatches
31 control sample 177 to 224 .tangle-solidup. control samples 273
to 320 control samples 145 to 176 .DELTA. control samples 369 to
400 .largecircle. control samples 33 to 64 X control samples 1 to
32 .circle-solid. control samples 113 to 144 .diamond. control
samples 412 to 443 .diamond-solid. control samples 401 to 412
.box-solid. invention samples
[0167] FIG. 10 Dispersion Quality and MW Sol of NR Masterbatches
(Region I)
32 control samples 177 to 224 invention sample 10 control samples
145 to 176 invention sample 9 .largecircle. control samples 33 to
64 .quadrature. invention sample 4 X control samples 1 to 32
invention sample 1 .circle-solid. control samples 113 to 144
.box-solid. invention sample 8
[0168] FIG. 11 Dispersion Quality and MW Sol of NR Masterbatches
(Region II)
33 .tangle-solidup. control samples 273 to 320 .box-solid.
invention sample 14 .DELTA. control samples 389 to 400 .quadrature.
invention sample 21
[0169] FIG. 12 Dispersion Quality and MW Sol of NR Masterbatches
(Region III)
34 .diamond-solid. control samples 401 to 412 .box-solid. invention
sample 22 .diamond. control samples 412 to 443 .quadrature.
invention sample 23
[0170] FIG. 13 Dispersion Quality and MW Sol of NR Masterbatches
(N330 Carbon Black, 55 phr)
35 .circle-solid. control samples 1 to 32 .box-solid. invention
samples 1 to 3
[0171] FIG. 14 Dispersion Quality and MW Sol of NR Masterbatches
(REGAL 250 Carbon Black)
36 .circle-solid. control samples 33 to 64 .box-solid. invention
sample 4 .largecircle. control sample 65 to 80 .quadrature.
invention sample 5 .diamond. control samples 81 to 96 .DELTA.
inventon sample 6 .diamond-solid. control samples 97 to 112
.tangle-solidup. inventon sample 7
[0172] FIG. 15 Dispersion Quality and MW Sol of NR Masterbatches
(BLACK PEARL 800 Carbon Black, 55 phr)
37 .circle-solid. control samples 113 to 144 .box-solid. invention
sample 8
[0173] FIG. 16 Dispersion Quality and MW Sol of NR Masterbatches
(N326 Carbon Black, 55 phr)
38 .circle-solid. control samples 145 to 176 .box-solid. invention
sample 9
[0174] FIG. 17 Dispersion Quarry and MW sol of NR Masterbatches
(REGAL 660 Carbon Black)
39 .circle-solid. control samples 177 to 224 .box-solid. invention
sample 10 .largecircle. control samples 225 to 240 .quadrature.
invention sample 11 .diamond. control samples 241 to 256 .DELTA.
invention sample 12 .diamond-solid. control samples 257 to 272
.tangle-solidup. invention sample 13
[0175] FIG. 18 Dispersion Quality and MW sol of NR Masterbatches
(N234 Carbon Black)
40 .circle-solid. control sampleS 273 to 320 .box-solid. invention
samples 14 to 17 .largecircle. control samples 337 to 352
.quadrature. invention sample 19 .diamond. control samples 321 to
338 .DELTA. invention sample 18 .diamond-solid. control samples 353
to 368 .tangle-solidup. invention sample 20
[0176] FIG. 19 Dispersion Quality and MW Sol of NR Masterbatches
(N1110 Carbon Black, 55 phr)
41 .circle-solid. control samples 369 to 400 .box-solid. invention
sample 21
[0177] FIG. 20 Dispersion Quality and MWsol of NR Masterbatches
(N351 Carbon Black, 33 phr)
42 .circle-solid. control samples 401 to 412 .box-solid. invention
sample 22
[0178] FIG. 21 Dispersion Quality and MW Sol of NR Masterbatches
(STERLING 6740 Carbon Black, 55 phr)
43 .circle-solid. control samples 412 to 443 .box-solid. invention
sample 23
[0179] FIG. 22 MW sol Effect on Crack Growth Rate (NR Compounds
Containing N234 Carbon Black@ 55 phr Loading)
44 .circle-solid. control sample 273 to 288 .quadrature. invention
sample 16
[0180] FIG. 23 MW sol Effect on Crack Growth Rate (NR Compounds
Containing N326 Carbon Black@ 55 phr Loading)
45 .circle-solid. control samples 145 to 160 .largecircle.
invention sample 9
[0181] FIG. 24 MW sol Effect on Crack Growth Rate (NR Compounds
Containing REGAL 660 Carbon Black @ 55 phr Loading)
46 .circle-solid. control samples 177 to 192 .sunburst. invention
sample 10
[0182] FIG. 25 Max Tan .delta. (Strain Sweep@60 C) of NR Compounds
Containing N234 Black at Different Loadings
47 .circle-solid. invention samples 24 to 28 .smallcircle.
invention samples 29 to 32 .sunburst. control sample 444 to 450
FIGURE CAPTIOPNS
[0183] FIG. 30 Macro-dispersion Quality and MW of Sol Portion of NR
Masterbatch Containing Dual Phase (Carbon Black/Silica)
Aggregates
48 .circle-solid. control samples 451 to 458 .box-solid. invention
sample 33 .smallcircle. control samples 459 to 466 .sunburst.
invention sample 34
[0184] FIG. 31 Macro-dispersion Quality and MW of Sol Portion of NR
Masterbatch Containing Blend of Carbon Black and Silica
49 .circle-solid. control samples 491 to 498 .box-solid. invention
sample 38 .smallcircle. control samples 483 to 490 .sunburst.
invention sample 37 .smallcircle. control samples 475 to 482
.sunburst. invention sample 36 .circle-solid. control samples 467
to 474 .box-solid. invention sample 35
[0185] The macro-dispersion values for the elastomer composites of
the invention shown in FIG. 9 are described by the following
equations:
D(%)<0.2% (1)
[0186] when MW.sub.sol is less than 0.45.times.10.sup.6; and
log (D)<log
(0.2)+2.0.times.[MW.sub.sol-(0.45.times.10.sup.6)].times.10-
.sup.-6 (2)
[0187] when
0.45.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6.
[0188] It will be recognized from the discussion above, that
macro-dispersion D (%) in the above equation (1) is the percent
undispersed area measured for defects greater than 10 microns. It
can be seen in FIG. 9 that D (%) equal to 0.2% is the threshold
macro-dispersion quality for all carbon blacks in Regions I, II and
III for natural rubber dry masterbatches. That is, none of the dry
masticated masterbatches achieved macro-dispersion quality of 0.2%
at any MW.sub.sol, even after mixing sufficiently to degrade
MW.sub.sol below 0.45.times.10.sup.6, as described by equation (1)
above. When the MW.sub.sol of the dry masterbatch control samples
shown in FIG. 9 is between 0.45.times.10.sup.6 and
1.1.times.10.sup.6, the dispersion quality is even poorer while, in
contrast, the dispersion quality of the invention samples having
MW.sub.sol in that range remains excellent. None of the preferred
embodiments shown in FIG. 9 having MW.sub.sol between
0.45.times.10.sup.6 and 1.1.times.10.sup.6 exceeds the preferred
macro-dispersion limit of 0.2%. In that regard, it should be
understood that the data points for preferred embodiments which are
seen in FIG. 9 (and in other Figures discussed below) to lie on the
X axis (i.e., at D (%) value of 0.1%) may have macro-dispersion
quality of 0.1% or an even better (i.e., lower) D (%) value.
[0189] Region I Carbon Black Samples
[0190] Invention samples comprising carbon blacks having
morphological properties (i.e., structures and surface area) of
Region I in FIG. 8, and corresponding control samples described
above made with such Region I carbon blacks, are compared in the
semi-log plot of FIG. 10. Specifically, FIG. 10 shows the
macro-dispersion values and MW.sub.sol values of the invention
samples and corresponding control samples comprising the carbon
blacks Regal.RTM. 660, N326, Regal.RTM. 250, N330, and Black
Pearl.RTM. 800, at carbon black loading ranging from 30 phr to 75
phr and extender oil loading ranging from 0 phr to 20 phr.
Excellent carbon black dispersion is seen in FIG. 10 for all of the
invention samples, representing preferred embodiments of elastomer
composites in accordance with the present disclosure. All of the
invention samples advantageously are below line 101 in FIG. 10,
whereas all of the control samples have poorer dispersion, being
above line 101. In fact, the preferred embodiments shown in FIG.
10, even through comprising carbon blacks from Region I, the most
difficult to disperse, all fall below a D (%) value of 0.3%. The
most preferred embodiments all have a D (%) value not exceeding
0.2% even at an MW.sub.sol value advantageously exceeding
0.7.times.10.sup.6. The data shown in FIG. 10 clearly reveals that
the macro-dispersion quality of the novel elastomer composites
disclosed here comprising Region I carbon blacks, over a wide range
of MW.sub.sol values, is significantly superior to that achievable
using comparable ingredients by prior dry mastication mixing
methods. The macro-dispersion values for the elastomer composites
of the invention shown in FIG. 10 are described by the following
equations:
D(%)<1.0% (3)
[0191] when MW.sub.sol is less than 0.7.times.10.sup.6; and
log D<log
(1.0)+2.5.times.[MW.sub.sol-(0.7.times.10.sup.6)].times.10.su- p.-6
(4)
[0192] when
0.7.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6
[0193] It will be recognized that D (%) is the percent undispersed
area measured for defects greater than 10 microns and 1% is the
threshold macro-dispersion quality for all carbon blacks in Region
I for natural rubber masterbatches in accordance with the present
invention. That is, none of the dry masticated masterbatches
achieved macro-dispersion quality of 1.0% or better at any
MW.sub.sol, even after dry mixing sufficiently to degrade
MW.sub.sol below 0.7.times.10.sup.6, as described by Equation (3)
above. When the MW.sub.sol of the dry masterbatch control samples
shown in FIG. 10 is between 0.7.times.10.sup.6 and
1.1.times.10.sup.6, the dispersion quality is even poorer. In
contrast, the dispersion quality of the invention samples having
MW.sub.sol in that range remains excellent. The preferred
embodiment shown in FIG. 10 having MW.sub.sol between
0.7.times.10.sup.6 and 1.1.times.10.sup.6 falls well below the
preferred macro-dispersion limit of 0.2%. It can be seen that the
elastomer composites of the invention comprising carbon blacks from
Region I provide heretofore unachieved balance between
macro-dispersion quality and MW.sub.sol.
[0194] Region H Carbon Black Samples
[0195] Invention samples comprising carbon blacks having
morphological properties (i.e., structure and surface area) of
Region II in FIG. 8, and corresponding control samples described
above made with such Region II carbon blacks are compared in the
semi-log plot of FIG. 11. Specifically, FIG. 11 shows the
macro-dispersion values and MW.sub.sol values of the invention
samples and corresponding control samples comprising the carbon
blacks N234 and N110 at carbon black loading ranging from 40 phr to
70 phr and extender oil loading ranging from 0 phr to 10 phr.
Excellent carbon black dispersion is seen in FIG. 11 for all of the
invention samples, representing preferred embodiments of elastomer
composites in accordance with the present disclosure. The invention
samples advantageously are below line 111 in FIG. 11, whereas all
of the control samples have poorer dispersion, being above line
111. In fact, the preferred embodiments shown in FIG. 11 comprising
carbon blacks from Region HI fall below a D (%) value of 0.3%. Most
preferred embodiments have a D (%) value not exceeding 0.2% at any
MW.sub.sol value. The data shown in FIG. 11 clearly reveal that the
macro-dispersion quality of the novel elastomer composites
disclosed here comprising Region II carbon blacks, over a wide
range of MW.sub.sol values, is significantly superior to that
achievable using comparable ingredients in prior dry mixing
methods. The macro-dispersion values for the elastomer composites
of the invention shown in FIG. 11 are described by the following
equations:
D(%)<0.3% (5)
[0196] when MW.sub.sol is less than 0.35.times.10.sup.6; and
log D<log
(0.3)+2.8.times.[MW.sub.sol-(0.35.times.10.sup.6)].times.10.s- up.6
(6)
[0197] when
0.35.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6.
[0198] It will be recognized that D (%) of 0.30% is the threshold
macro-dispersion quality for all carbon blacks in Region II for
natural rubber masterbatches in accordance with the present
invention, and 0.35.times.10.sup.6 is the threshold MW.sub.sol
value. That is, none of the dry masterbatches achieved
macro-dispersion quality of 0.30% or better at any MW.sub.sol even
after dry mixing sufficiently to degrade MW.sub.sol below
0.35.times.10.sup.6, as described by Equation (5) above. When the
MW.sub.sol of the dry masterbatch control samples shown in FIG. 11
is between 0.35.times.10.sup.6 and 1.1.times.10.sup.6, the
dispersion quality is even poorer. In contrast, the dispersion
quality of the invention samples having MW.sub.sol in that range
remains excellent The preferred embodiments shown in FIG. 11 having
MW.sub.sol between 0.35.times.10.sup.6 and 1.1.times.10.sup.6 fall
well below the preferred macro-dispersion limit of 0.2%. It can be
seen that the elastomer composites of the invention comprising
carbon blacks from Region II provide heretofore unachieved balance
between macro-dispersion quality and MW.sub.sol.
[0199] Region III Carbon Black Samples
[0200] Invention samples comprising carbon blacks having
morphological properties (i.e., structures and surface area) of
Region III in FIG. 8, and corresponding control samples described
above made with such Region III carbon blacks are compared in the
semi-log plot of FIG. 12. Specifically, FIG. 12 shows the
macro-dispersion values and MW.sub.sol values of the invention
samples and corresponding control samples comprising the carbon
blacks N351 and Sterling 6740, at carbon black loading ranging from
30 phr to 70 phr and extender oil loading ranging from 0 phr to 20
phr. Excellent carbon black dispersion is seen in FIG. 12 for all
of the invention samples, representing preferred embodiments of
elastomer composites in accordance with the present disclosure. All
of the invention samples advantageously are below line 121 in FIG.
12, whereas all of the control samples have poorer dispersion,
being above line 121. In fact, the preferred embodiments shown in
FIG. 12, comprising carbon blacks from Region III, fall at or below
a D (%) value of 0.1%, even at an MW.sub.sol value advantageously
exceeding 0.3.times.10.sup.6 and even 0.7.times.10.sup.6. The data
shown in FIG. 12 clearly reveals that the macro-dispersion quality
of the novel elastomer composites disclosed here comprising Region
III carbon black, over a wide range of MW.sub.sol values, is
significantly superior to that achievable using comparable
ingredients in prior dry mixing methods. The macro-dispersion
values for the elastomer composites of the invention shown in FIG.
12 are described by the following equations.
D(%)<0.1% (7)
[0201] when MW.sub.sol is less than 0.35.times.10.sup.6; and
log D<log
(0.1)+2.0.times.[MW.sub.sol-(0.30.times.10.sup.6).times.10.su-
p.-6] (8)
[0202] when
0.30.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6.
[0203] It will be recognized that D (%) of 0.1% is the threshold
macro-dispersion quality for all carbon blacks in Region III for
natural rubber masterbatches in accordance with the present
invention, and 0.3.times.10.sup.6 is the threshold MW.sub.sol
value. That is, none of the dry masterbatches achieved
macro-dispersion quality of 0.1% at any MW.sub.sol, even after dry
mixing sufficiently to degrade MW., below 0.35.times.10.sup.6, as
described by Equation (7) above. When the MW.sub.sol of the dry
masterbatch control samples shown in FIG. 12 is between
0.30.times.10.sup.6 and 1.1.times.10.sup.6, the dispersion quality
is even poorer. In contrast, the dispersion quality of the
invention samples having MW.sub.sol in that range remains
excellent. The preferred embodiments shown in FIG. 12 having
MW.sub.sol between 0.30.times.10.sup.6 and 1.1.times.10.sup.6 fall
well below the preferred macro-dispersion limit of 0.2%, and, in
fact, are at or below D (%) value of 0.1%. It can be seen that the
elastomer composites of the present invention comprising carbon
blacks from Region III provide heretofore unachieved balance
between macro-dispersion quality and MW.sub.sol.
[0204] Additional Sample Comparisons
[0205] The macro-dispersion values for the invention samples are
shown graphically in the semi-long plots of FIGS. 13 through 21, as
a function of their MW.sub.sol values, as in FIGS. 8 through 12
discussed above. More specifically, in FIGS. 13 through 21 all
invention samples described above comprising a particular carbon
black (being limited to those of a specific carbon black loading
when so indicated) are shown together in a single semi-log plot
together with the corresponding control samples. (See the legends
above giving the reference numbers of the invention samples and
control samples included in each figure.) Thus, FIG. 13 shows the
dispersion quality and MW.sub.sol of invention and control samples
described above comprising 55 phr N330 carbon black The data shown
in FIG. 13 clearly reveals that the macro-dispersion quality of the
novel elastomer composites of the invention, comprising N330 carbon
black, over a wide range of MW.sub.sol values, is significantly
superior to that of the control samples. Macro-dispersion for
elastomer composites of the invention comprising N330 carbon black,
as shown in FIG. 13 is described by the following equations:
D(%)<1% (9)
[0206] when MW.sub.sol<0.6.times.10.sup.6; and
log (D)<log
(1)+2.5.times.[MW.sub.sol(0.6.times.10.sup.6)].times.10.sup- .-6
(10)
[0207] when
0.6.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6.
[0208] None of the dry masticated masterbatches achieved
macro-dispersion quality of 1.0% at any MW.sub.sol, even after dry
mixing sufficiently to degrade MW.sub.sol below 0.6.times.10.sup.6
(see Equation 9, above). In control samples comprising 55 phr N330
carbon black in which the MW.sub.sol was maintained between
0.6.times.10.sup.6 and 1.1.times.10.sup.6, the D (%) value is even
higher, such as more than 4% undispersed area.
[0209] FIG. 14 shows the dispersion quality and MW.sub.sol of the
invention and control samples described above comprising REGAL.RTM.
250 carbon black. Selected invention and control samples shown in
FIG. 14 comprised oil, as set forth above. The data shown in FIG.
14 clearly reveals that the macro-dispersion quality of the novel
elastomer composites of the invention comprising REGAL.RTM. 250
carbon black, over a wide range of MW.sub.sol values, is
significantly superior to that of the control samples. The
macro-dispersion values for the elastomer composites of the
invention comprising REGAL.RTM. 250 carbon black, as shown in FIG.
14 are described by the following equations:
D(%)<1% (9)
[0210] when MW.sub.sol<0.6.times.10.sup.6; and
log (D)<log
(1)+2.5.times.[MW.sub.sol-(0.6.times.10.sup.6)].times.10.su- p.-6
(10)
[0211] when
0.6.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6.
[0212] None of the control samples achieved macro-dispersion
quality of 1.0% or better at any MW.sub.sol even after dry mixing
sufficiently to degrade MW.sub.sol below 0.6.times.10.sup.6. In
contrast, elastomer composites of the invention comprising
Regal.RTM. 250 carbon black and having MW.sub.sol above
0.6.times.10.sup.6 have excellent macro-dispersion, such as D (%)
less than 0.2%. Compound properties and performance characteristics
for the invention and control samples shown in FIG. 14, comprising
REGAL.RTM. 250 carbon black, are set forth in Table 27 below. It
can be seen that invention sample No. 4 has exceptionally good
resistance to crack growth, as indicated by its very low crack
growth rate value of only 0.92 cm/million cycles. In fact, the
invention sample is far superior to the corresponding control
samples. This is believed to be due largely to the better
MW.sub.sol and macro-dispersion of carbon black in the invention
sample, as discussed above.
50TABLE 27 Compound Properties of NR Compounds Containing REGAL 250
Carbon Black at 55 phr Loading Mooney Crack Growth Tan Tan Sample
ML(1 + 4) @ Hard- E100 E300 Tensile EB Re- Rate (cm/ Abrasion loss
.delta. @ .delta. @ No. 100 C. ness (psi) (psi) (psi) (%) bound
million cycles) (g) 0.degree. C. 60.degree. C. control 33 60.63
55.35 181.26 999.82 4090.24 675.0 64.50 2.00 0.191 0.167 0.091
control 34 73.58 57.80 235.14 1293.88 3978.24 595.0 64.55 1.83
0.182 0.155 0.083 control 35 81.49 58.65 243.66 1265.26 4103.41
613.0 63.75 2.38 0.192 0.150 0.091 control 36 84.04 59.95 244.23
1215.87 3960.32 614.0 63.30 1.42 0.192 0.162 0.091 control 37 57.35
56.75 215.70 1259.99 4119.85 502.0 64.65 3.00 0.165 0.176 0.100
control 38 60.10 57.05 316.75 1206.00 4023.65 620.0 63.45 2.99
0.163 0.184 0.099 control 39 66.28 57.25 225.44 1256.23 4134.06
621.0 63.90 2.17 0.186 0.170 0.092 control 40 77.40 59.10 255.15
1330.87 4059.01 597.0 62.30 1.69 0.182 0.175 0.093 control 41 44.40
56.25 216.00 1214.78 4038.68 618.0 64.20 2.84 0.190 0.189 0.102
control 42 47.96 56.50 214.53 1202.93 3944.05 613.0 64.20 3.24
0.182 0.168 0.103 control 43 50.10 56.60 210.50 1140.90 4058.33
638.0 64.50 3.52 0.177 0.183 0.101 control 45 36.82 52.90 177.47
982.86 3790.56 533.0 63.90 3.50 0.179 0.185 0.104 control 46 38.23
54.50 198.63 1111.04 3860.56 629.0 63.80 3.86 0.199 0.197 0.104
control 47 35.35 54.60 199.03 1110.00 3871.49 505.0 64.35 3.81
0.192 0.106 control 48 40.58 55.50 204.52 1139.94 3961.06 632.0
63.65 3.45 0.180 0.182 0.110 invention 71.97 57.00 218.18 1230.30
4036.30 611.0 64.70 0.92 0.190 0.148 0.096 4
[0213] FIG. 15 shows the dispersion quality and MW.sub.sol of the
invention and control samples described above comprising BLACK
PEARL.RTM. 800 carbon black at 55 phr loading. The data shown in
FIG. 15 clearly reveals that the macro-dispersion quality of the
novel elastomer composites of the invention comprising Black
Pearl.RTM. 800 carbon black, is significantly superior to that of
the control samples. The macro-dispersion values for elastomer
composites of the invention comprising Black Pearl.RTM. 800 carbon
black, as shown in FIG. 15, are described by the following
equations:
D(%)<1.5% (11)
[0214] when MW.sub.sol<0.65.times.10.sup.6; and
log (D)<log
(1.5)+2.5.times.[MW.sub.sol-(0.65.times.10.sup.6)].times.10-
.sup.-6 (12)
[0215] when
0.65.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6.
[0216] None of the control samples achieved macro-dispersion
quality of 1.0% or better at any MW.sub.sol even after dry mixing
sufficiently to degrade MW.sub.sol below 0.65.times.10.sup.6. In
contrast, elastomer composites of the invention comprising Black
Pearl.RTM. 800 carbon black and having MW.sub.sol above
0.65.times.10.sup.6 have excellent macro-dispersion, such as D (%)
less than 0.2%. Compound properties and performance characteristics
for the invention and control samples shown in FIG. 15, comprising
Black Pearl.RTM. 800 carbon black, are set forth in Table 28 below.
It can be seen that invention sample No. 8 has exceptionally good
resistance to crack growth, as indicated by its very low crack
growth rate value of only 0.27 cm/million cycles. In fact, the
invention samples are far superior to the corresponding control
samples. This is believed to be due largely to the better
MW.sub.sol and macro-dispersion of carbon black in the invention
sample, as discussed above.
51TABLE 28 Compound Properties of NR Compounds Containing BLACK
PEARL 800 Carbon Black at 65 phr Loading Crack Growth Tan Tan
Sample Mooney E100 E300 Tensile EB Rate (cm/ Abrasion loss .delta.
@ .delta. @ No. ML(1 + 4) @ 100 C. Hardness (psi) (psi) (psi) (%)
Rebound million cycles) (g) 0.degree. C. 60.degree. C. control
110.5 66.4 345.0 1333.0 3878.0 598 44.7 3.14 0.148 0.281 0.184 113
control 109.0 67.3 367.0 1427.0 4033.0 606 45.0 2.72 0.125 0.274
0.185 114 control 106.4 67.2 363.0 1311.0 3896.0 610 47.0 2.53
0.163 0.233 0.171 115 control 105.7 69.0 322.0 1202.0 3856.0 626
46.6 2.41 0.194 0.244 0.163 116 control 110.6 67.1 316.0 1400.0
4180.0 616 40.9 4.56 0.086 0.327 0.214 117 control 118.9 67.1 310.0
1395.0 3967.0 607 41.8 2.80 0.112 0.335 0.225 118 control 111.9
67.7 309.0 1323.0 4149.0 634 41.7 4.33 0.091 0.321 0.216 119
control 110.6 67.6 373.0 1188.0 4199.0 653 42.1 3.89 0.095 0.301
0.207 120 control 114.7 66.3 287.0 1262.0 4329.0 667 39.2 3.38
0.075 0.312 0.256 121 control 110.5 65.8 288.0 1223.0 4217.0 659
38.7 4.58 0.108 0.344 0.236 122 control 115.0 67.5 280.0 1282.0
4071.0 624 40.2 4.79 0.103 0.329 0.232 123 control 116.5 66.5 309.0
1388.0 4166.0 623 41.7 3.78 0.102 0.321 0.209 124 control 113.4
65.4 281.0 1274.0 3978.0 631 38.9 3.40 0.076 0.352 0.248 125
control 101.4 66.8 280.0 1222.0 4260.0 656 38.1 5.57 0.070 0.355
0.241 126 control 105.5 66.4 262.0 1150.0 4167.0 670 38.2 4.79
0.073 0.346 0.254 127 control 110.7 66.8 292.0 1301.0 4209.0 643
39.4 3.40 0.113 0.357 0.23 128 invention 131.3 62.5 227.0 1291.0
3418.0 532 44.8 0.27 0.130 0.297 0.199 8
[0217] FIG. 16 shows the dispersion quality and MW.sub.sol of the
invention and control samples described above comprising N326
carbon black at 55 phr loading. The data shown in FIG. 16 clearly
reveals that the macro-dispersion quality of the novel elastomer
composites of the invention comprising N326 carbon black is
significantly superior to that of the control samples. The
macro-dispersion values for the elastomer composites of the
invention comprising N326 carbon black, as shown in FIG. 16, are
described by the following equations:
D(%)<1% (13)
[0218] when MW.sub.sol<0.7.times.10.sup.6; and
log (D)<log
(1)+2.5.times.[MW.sub.sol-(0.7.times.10.sup.6)].times.10.su- p.-6
(14)
[0219] when
0.7.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6.
[0220] None of the control samples achieved macro-dispersion
quality of 1.0% or better at any MW.sub.sol even after dry mixing
sufficiently to degrade MW.sub.sol below 0.7.times.10.sup.6. In
contrast, elastomer composites of the invention comprising N326
carbon black and having MW.sub.sol above 0.7.times.10.sup.6 have
excellent macro-dispersion, such as D (%) not greater than 0.2%.
Compound properties and performance characteristics for the
invention and control samples shown in FIG. 16, comprising N326
carbon black are set forth in Table 29 below. It can be seen that
invention sample No. 9 has exceptionally good resistance to crack
growth, as indicated by its very low crack growth rate value of
only 0.77 cm/million cycles. In fact, the invention sample is far
superior to the corresponding control samples. This is believed to
be due largely to the better MW.sub.sol and macro-dispersion of
carbon black in the invention sample, as discussed above.
52TABLE 29 Compound Properties of NR Compounds Containing M326
Carbon Black at 55 phr Loading Crack Growth Tan Tan Sample Mooney
E100 E300 Tensile EB Rate (cm/ Abrasion loss .delta. @ .delta. @
No. ML(1 + 4) @ 100 C. Hardness (psi) (psi) (psi) (%) Rebound
million cycles) (g) 0.degree. C. 60.degree. C. control 64.6 60.5
289 1713 3921 546 57.8 2.84 0.0952 0.225 0.129 145 control 88.2
62.4 340 1802 4094 553 58.1 2.52 0.0887 0.217 0.126 146 control
91.7 63.3 391 1917 3991 528 57.6 2.03 0.0946 0.205 0.123 147
control 96.8 64.3 326 1664 4045 572 56.3 1.63 0.0927 0.221 0.129
148 control 62.4 61.5 310 1763 4029 552 57.2 3.39 0.0827 0.234
0.142 149 control 67.7 62.6 326 1855 4055 551 56.8 2.77 0.0866
0.234 0.150 150 control 76.5 60.6 287 1641 4015 575 55.6 2.61
0.0933 0.241 0.149 151 control 79.4 63.6 329 1720 3980 559 54.5
2.79 0.0857 0.249 0.155 152 control 57.2 60.1 282 1623 3968 579
55.4 3.12 0.0911 0.258 0.170 153 control 57.2 62.8 354 1889 3879
525 56.0 3.35 0.0858 0.241 0.147 154 control 57.3 62.2 323 1763
3975 556 55.4 3.63 0.0811 0.254 0.152 155 control 60.1 61.9 310
1667 3918 564 54.9 3.55 0.0906 0.261 0.153 156 control 45.1 61.2
328 1748 3768 533 55.5 3.02 0.0931 0.254 0.149 157 control 50.1
60.6 315 1740 3817 546 55.4 3.81 0.0914 0.249 0.150 158 control
53.2 61.3 306 1675 3886 563 54.9 3.23 0.0933 0.240 0.158 159
control 50.5 62.6 331 1752 3884 549 55.2 3.19 0.0942 0.246 0.163
150 invention 77.8 60.9 277 1563 4167 593 58.4 0.77 0.0939 0.225
0.136 9
[0221] FIG. 17 shows the dispersion quality and MW.sub.sol of the
invention and control samples described above comprising REGAL
(trademark) 660 carbon black, Selected invention and control
samples shown in FIG. 17 comprised oil as set forth above. The data
shown in FIG. 17 clearly reveals that the macro-dispersion quality
of the novel elastomer composites of the invention comprising
REGAL.RTM. 660 carbon black, over a wide range of MW.sub.sol
values, is significantly superior to that of the control samples.
The macro-dispersion values for the elastomer composites of the
invention comprising REGAL.RTM. 660 carbon black, as shown in FIG.
17 are described by the following equations:
D(%)<1% (15)
[0222] when MW.sub.sol<0.6.times.10.sup.6; and
log (D)<log
(1)+2.5.times.[MW.sub.sol-(0.6.times.10.sup.6)].times.10.su- p.-6
(16)
[0223] when
0.6.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6.
[0224] None of the control samples achieved macro-dispersion
quality of 1.0% or better at any MW.sub.sol even after dry mixing
sufficiently to degrade MW.sub.sol below 0.6.times.10.sup.6. In
contrast, elastomer composites of the invention comprising
Regal.RTM. 660 carbon black and having MW.sub.sol above
0.6.times.10.sup.6 have excellent macro-dispersion, such as D (%)
less than 0.2%. Compound properties and performance characteristics
for the invention sample No. 10 and various control samples shown
in FIG. 17, comprising Regal.RTM. 660 carbon black, are set forth
in Table 30 below. It can be seen that invention sample No. 10 has
exceptionally good resistance to crack growth, as indicated by its
very low crack growth rate value of only 0.69 cm/million cycles. In
fact, the invention samples are far superior to the corresponding
control samples. This is believed to be due largely to the better
MW.sub.sol and macro-dispersion of carbon black in the invention
sample, as discussed above.
53TABLE 30 Compound Properties of NR Compounds Containing REGAL 660
Carbon Black at 55 phr Loading Crack Growth Tan Tan Sample Mooney
E100 E300 Tensile EB Rate (cm/ Abrasion loss .delta. @ .delta. @
No. ML(1 + 4) @ 100 C. Hardness (psi) (psi) (psi) (%) Rebound
million cycles) (g) 0.degree. C. 60.degree. C. control 61.0 213 942
702 54.6 0.131 177 control 87.6 63.2 232 943 4002 694 55.6 2.34
0.1649 0.194 0.129 178 control 87.1 64.9 285 1134 4016 644 53.7
2.78 0.1620 0.200 0.140 179 control 85.6 64.0 271 1198 4058 618
52.9 2.98 0.1385 0.220 0.153 180 control 80.1 61.0 206 945 4098 661
51.0 3.41 0.1189 0.267 0.185 181 control 93.4 59.0 192 835 3924 733
49.9 3.11 0.1076 0.270 0.194 182 control 89.0 61.0 215 920 4134 698
50.1 3.15 0.1086 0.264 0.192 183 control 83.4 62.4 223 996 4236 694
48.0 3.11 0.1085 0.284 0.208 184 control 70.1 60.0 178 794 3768 717
47.5 4.59 0.0937 0.306 0.209 185 control 69.8 60.3 196 920 4051 666
48.5 4.06 0.1008 0.295 0.211 186 control 76.7 63.5 166 866 4157 720
47.7 3.53 0.1041 0.297 0.198 187 control 72.1 62.0 191 883 4182 704
47.8 3.79 0.0985 0.285 0.207 188 control 54.3 61.2 222 1079 4240
674 47.5 3.71 0.0957 0.306 0.203 189 control 55.7 61.1 193 942 4125
692 46.8 4.14 0.0962 0.300 0.200 190 control 65.0 47.4 0.226 191
control 61.1 60.4 191 902 4189 710 46.5 4.78 0.0897 0.301 0.226 192
invention 88.1 62.9 249 1202 4292 634 48.2 0.69 0.0942 0.271 0.178
10
[0225] FIG. 18 shows the dispersion quality and MW.sub.sol of the
invention and control samples described above comprising N234
carbon black. Selected invention and control samples shown in FIG.
18 comprised oil, as set forth above. The data shown in FIG. 18
clearly reveals that the macro-dispersion quality of the novel
elastomer composites of the invention comprising N234 carbon black,
over a wide range of MW.sub.sol values, is significantly superior
to that of the control samples. The macro-dispersion values for the
elastomer composites of the invention comprising N234 carbon black,
as shown in FIG. 18 are described by the following equations:
D(%)<0.3% (17)
[0226] when MW.sub.sol<0.35.times.10.sup.6; and
log (D)<log
(0.3)+2.8.times.[MW.sub.sol-(0.35.times.10.sup.6)].times.10-
.sup.-6 (18)
[0227] when
0.35.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6.
[0228] None of the control samples achieved macro-dispersion
quality of 0.3% or better at any MW.sub.sol even after dry mixing
sufficiently to degrade MW.sub.sol below 0.35.times.10.sup.6. In
contrast, elastomer composites of the invention comprising N234
carbon black and having MW.sub.sol greater than 0.35.times.10.sup.6
have excellent macro-dispersion, such as D (%) not more than 0.3%.
or even 0.2%. Compound properties and performance characteristics
for invention sample No. 14 and various control samples shown in
FIG. 18, comprising N234 carbon black, are set forth in Table 31
below. It can be seen that invention sample No. 14 has good
resistance to crack growth, as indicated by its crack growth rate
value of only 2.08 cm/million cycles.
54TABLE 31 Compound Properties of NR Compounds Containing N234
Carbon Black at 55 phr Loading Crack Growth Tan Tan Sample Mooney
E100 E300 Tensile EB Rate (cm/ Abrasion loss .delta. @ .delta. @
No. ML (1 + 4) @ 100 C. Hardness (psi) (psi) (psi) (%) Rebound
million cycles) (g) 0.degree. C. 60.degree. C. control 94.5 68.0
386 2077 3716 511 45.9 2.14 0.0563 0.285 0.183 273 control 121.6
69.6 464 2299 3925 501 47.2 1.84 0.0583 0.274 0.173 274 control
121.4 72.5 564 2545 3994 472 46.1 1.70 0.0538 0.294 0.172 275
control 132.2 71.9 511 2259 3964 520 46.9 1.21 0.0620 0.270 0.173
276 control 79.6 68.5 468 2453 3857 469 47.1 2.22 0.0628 0.305
0.173 277 control 96.3 70.0 531 2499 3874 469 45.8 2.40 0.0634
0.299 0.196 278 control 108.6 69.0 406 2131 3863 532 45.4 2.00
0.0680 0.306 0.198 279 control 120.3 71.5 476 2273 3852 502 44.2
1.81 0.0646 0.298 0.198 280 control 76.4 69.7 556 2723 4027 451
46.3 3.10 0.0598 0.293 0.174 281 control 89.8 69.8 553 2574 3896
455 46.5 2.33 0.0537 0.307 0.182 282 control 93.6 69.6 506 2416
3867 475 46.4 2.41 0.0594 0.309 0.186 283 control 106.7 71.8 526
2384 3788 484 44.2 1.99 0.0579 0.304 0.190 284 control 73.3 69.3
529 2586 3831 444 47.0 2.99 0.0554 0.295 0.178 285 control 79.2
69.5 531 2574 3856 456 45.6 2.85 0.0551 0.294 0.172 286 control
77.8 70.7 544 2485 3834 461 45.4 2.93 0.0569 0.305 0.187 287
control 82.8 71.2 485 2295 3799 499 44.0 2.39 0.0647 0.316 0.198
288 invention 82.6 71.5 500 2440 3883 531 45.1 2.08 0.0698 0.310
0.198 14
[0229] FIG. 19 shows the dispersion quality and MW.sub.sol of the
invention and control samples described above comprising N110
carbon black at 55 phr loading. The data shown in FIG. 19 clearly
reveals that the macro-dispersion quality of the novel elastomer
composites of the invention comprising N110 carbon black, over a
wide range of MW.sub.sol values, is significantly superior to that
of the control samples. The macro-dispersion values for the
elastomer composites of the invention comprising N110 carbon black,
as shown in FIG. 19, are described by the following equations:
D(%)<0.5% (19)
[0230] when MW.sub.sol<0.35.times.10.sup.6; and
log (D)<log
(0.5)+2.5.times.[MW.sub.sol-(0.6.times.10.sup.6)].times.10.- sup.-6
(20)
[0231] when
0.35.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6.
[0232] None of the control samples achieved macro-dispersion
quality of 0.5% at any MW.sub.sol even after dry mixing
sufficiently to degrade MW.sub.sol below 0.35.times.10.sup.6. In
contrast, elastomer composites of the invention comprising N110
carbon black and having MW.sub.sol above 0.35.times.10.sup.6 have
excellent macro-dispersion, such as D (%) less than 0.2%.
[0233] FIG. 20 shows the dispersion quality and MW.sub.sol of
invention sample 22 and the control samples described above
comprising N351 carbon black at 33 phr loading. The data shown in
FIG. 20 clearly reveals that the macro-dispersion quality of the
novel elastomer composites of the invention comprising N351 carbon
black, over a wide range of MW.sub.sol values, is significantly
superior to that of the control samples. The macro-dispersion
values for the elastomer composites of the invention comprising
N351 carbon black, as shown in FIG. 20, are described by the
following equations:
D(%)<0.3% (21)
[0234] when MW.sub.sol<0.55.times.10.sup.6; and
log (D)<log
(0.3)+2.0.times.[MW.sub.sol-(0.55.times.10.sup.6)].times.10-
.sup.-6 (22) when
0.55.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.- 6.
[0235] None of the control samples achieved macro-dispersion
quality of 1.0% at any MW.sub.sol, even after dry mixing
sufficiently to degrade MW.sub.sol below 0.35.times.10.sup.6. In
contrast, elastomer composites of the invention comprising N351
carbon black and having MW.sub.sol above 0.35.times.10.sup.6 have
excellent macro-dispersion, such as D (%) less than 0.2%.
[0236] FIG. 21 shows the dispersion quality and MW.sub.sol of the
invention sample No. 23 and control samples described above
comprising STERLING.RTM. 6740 carbon black at 55 phr loading. The
data shown in FIG. 21 clearly reveals that the macro-dispersion
quality of the novel elastomer composites of the invention
comprising STERLING.RTM. 6740 carbon black, over a wide range of
MW.sub.sol values, is significantly superior to that of the control
samples. The macro-dispersion values for the elastomer composites
of the invention comprising STERLING.RTM. 6740 carbon black, as
shown in FIG. 21 are described by the following equations:
D(%)<0.1% (23)
[0237] when MW.sub.sol<0.3.times.10.sup.6; and
log (D)<log
(0.1)+2.0.times.[MW.sub.sol-(0.3.times.10.sup.6)].times.10.- sup.-6
(24)
[0238] when
0.3.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6.
[0239] None of the control samples achieved macro-dispersion
quality of 0. 1% or even 0.2% at any MW.sub.sol, even after dry
mixing sufficiently to degrade MW.sub.sol below 0.3.times.10.sup.6.
In contrast, elastomer composites of the invention comprising
STERLING.RTM. 6740 carbon black and having MW.sub.sol above
0.3.times.10.sup.6 have excellent macro-dispersion, such as D (%)
less than 0.2% and even less than 0.1%. Compound properties and
performance characteristics for invention sample No. 23 and the
control samples shown in FIG. 21, comprising STERLING.RTM. 4D 6740
carbon black, are set forth in Table 32 below. It can be seen that
invention sample No. 23 has good resistance to crack growth, as
indicated by its crack growth rate value of only 0.91 cm/million
cycles. In fact, the invention sample is far superior to the
corresponding control samples. This is believed to be due largely
to the better MW.sub.sol and macro-dispersion of carbon black in
the invention sample, as discussed above.
55TABLE 32 Compound Properties of NR Compounds Containing STERLING
6740 Carbon Black at 55 phr Loading Ten- Mooney Hard- E100 E300
sile EB Re- Crack Growth Rate Abrasion loss Tan .delta. @ Tan
.delta. @ Sample No. ML(1 + 4) @ 100.degree. C. ness (psi) (psi)
(psi) (%) bound (cm/million cycles) (g) 0.degree. C. 60.degree. C.
control 412 75.50 65.1 467.0 2308.0 3519 451 59.8 5.04 0.127 0.202
0.107 control 413 85.70 65.7 469.0 2314.0 3655 479 60.0 3.63 0.128
0.203 0.108 control 414 92.70 67.7 462.0 2243.0 3613 472 59.3 3.96
0.126 0.208 0.114 control 415 99.60 66.9 492.0 2260.0 3572 477 58.8
4.56 0.12 0.217 0.118 control 416 74.50 65.8 521.0 2468.0 3584 445
60.3 5.67 0.117 0.188 0.094 control 417 78.20 67.1 502.0 2372.0
3445 436 60.0 4.67 0.112 0.202 0.104 control 418 82.00 66.0 534.0
2418.0 3604 453 59.3 4.23 0.125 0.204 0.105 control 419 86.10 67.8
540.0 2330.0 3620 475 57.5 3.22 0.122 0.218 0.117 control 420 66.70
66.0 515.0 2382.0 3468 444 60.0 4.23 0.131 0.204 0.099 control 421
76.30 67.8 488.0 2310.0 3375 440 58.8 3.84 0.127 0.206 0.105
control 422 78.30 65.8 548.6 2440.0 3549 442 59.8 3.98 0.126 0.210
0.106 control 423 82.10 66.5 487.0 2219.0 3452 466 56.8 3.85 0.12
0.213 0.117 control 424 64.80 66.5 541.0 2448.0 3397 425 58.3 4.54
0.131 0.200 0.104 control 425 67.50 66.5 524.0 2374.0 3474 445 58.8
3.65 0.129 0.207 0.100 control 426 70.30 66.9 546.0 2351.0 3428 446
58.0 3.07 0.134 0.211 0.110 control 427 71.00 68.1 554.0 2340.0
3322 435 56.9 3.25 0.126 0.217 0.115 invention 23 110.50 64.8 453.6
2241.0 3324 443 57.3 0.91 0.1642 0.204 0.124
Addition Examples: Cured Samples
[0240] A number of the masterbatch samples described above,
including both selected invention samples and corresponding control
samples, were cured and tested. Specifically, samples were mixed
accordingly to Stage II in Table 8, above, using the formulation of
Table 9, to produce a final compound. The final compound in each
case was then cured in a mold using standard techniques at about
150.degree. C. until substantially complete cure was achieved.
Performance characteristics of the cured samples were determined by
measuring their respective crack growth rates in accordance with
the measurement technique set forth above, i.e., using a rotating
flexing machine per ASTM D3629-94. The rotating type flexing
machine used to measure crack growth is commercially available and
well known. It is discussed, for example, in the Proceedings of the
International Rubber Conference, 1995 (Kobe, Japan), Paper No. 27A
-6 (p. 472-475). The compounds were tested at 100.degree. C. and at
a 45.degree. flexing angle. It is generally accepted by those
skilled in the art that crack growth rate in such compounds is
affected by the molecular weight of the natural rubber and the
dispersion quality of the carbon black i.e., by the MW.sub.sol and
D (%) values of the compounds. Higher MW.sub.sol and lower D (%)
correlate well with reduced crack growth rate. The crack growth
rate and other information for invention samples nos. 9, 10 and 16
are set forth in Table 33 below. The corresponding test results for
corresponding control samples is set forth in Table 34 below,
grouped by choice of carbon black. Also, Tan .delta..sub.max@
60.degree. C. was measured for invention samples nos. 24-32 and for
corresponding control samples. The Tan .delta..sub.max@ 60.degree.
C. values for the invention samples are set forth in Table 35
below. The corresponding test results for control samples is set
forth in Table 36 below.
[0241] Control samples No. 444-450 shown in Table 36 were made in
accordance with the procedures described above for control sample
code M2D1 using RSS1 natural rubber. All used carbon black N234 at
the loading level (phr) shown in Table 36, along with 5 phr
extender oil.
56TABLE 33 Crack Growth Rate of invention Samples Invention Sample
No. CB/Loading/Oil Mw.sub.sol(K) CGR (cm/million cycles) 9
N326/55/0 666 0.77 10 R660/55/0 678 0.69 16 N234/55/0 500 0.88
[0242]
57TABLE 34 Crack Growth Rate of Control Samples RSS1 RSS1 Sample
Mw.sub.sel CGR Sample Mw.sub.sel CGR Code No. (K) (cm/million
cycles) Code No. (K) (cm/million cycles) N234/55phr/0 N326/55phr/0
M1D1 273 585 2.14 M1D1 145 550 2.84 M1D2 274 669 1.84 M1D2 146 636
2.52 M1D3 275 759 1.70 M1D3 147 650 2.03 M1D4 276 896 1.21 M1D4 148
724 1.63 M2D1 277 580 2.22 M2D1 149 517 3.39 M2D2 278 602 2.40 M2D2
150 572 2.77 M2D3 279 631 2.00 M2D3 151 572 2.61 M2D4 280 667 1.81
M2D4 152 696 2.79 M3D1 281 457 3.10 M3D1 153 489 3.12 M3D2 282 476
2.33 M3D2 154 521 3.35 M3D3 283 493 2.41 M3D3 155 504 3.63 M3D4 384
495 1.99 M3D4 156 538 3.55 M4D1 285 372 2.99 M4D1 157 415 3.02 M4D2
286 382 2.85 M4D2 158 447 3.81 M4D3 287 381 2.93 M4D3 159 466 3.23
M4D4 288 403 2.39 M4D4 160 469 3.19 Regal 660/55phr/0 Regal
660/55phr/0 M1D1 177 674 M3D1 185 473 4.59 M1D2 178 792 2.34 M3D2
186 506 4.06 M1D3 179 891 2.78 M3D3 187 562 3.53 M1D4 180 676 2.98
M3D4 188 559 3.79 M2D1 181 598 3.41 M4D1 189 401 3.71 M2D2 182 602
3.11 M4D2 190 426 4.14 M2D3 183 697 3.15 M4D3 191 466 M2D4 184 659
3.11 M4D4 192 449 4.78
[0243]
58TABLE 35 Tan .delta. at 60.degree. C. for Invention Samples
Invention N234 Loading/ Max. Tan .delta. @ Sample No. Oil (phr)
Mw.sub.sol(K) 60.degree. C. 24 48/5 569 0.169 25 53/5 485 0.176 26
58/5 447 0.191 27 63/5 403 0.219 28 68/5 378 0.227 29 49/5 618
0.159 30 54/5 482 0.171 31 63/5 390 0.228 32 65/5 325 0.224
[0244]
59TABLE 36 Tan .delta. at 60.degree. C. for Control Samples Sample
MW D N234 Loading/ Max. Tan D No. (K) (%) Oil (phr) (169 60 C.) 444
428 0.25 37/5 0.154 445 409 0.37 42/5 0.170 446 379 0.42 46/5 0.179
447 361 0.58 51/5 0.195 448 366 0.27 53/5 0.212 449 290 0.39 58/5
0.215 450 296 0.64 63/5 0.245
[0245] It can be seen from a comparison of Table 33 and 34 that
advantageously lower crack growth rate is achieved by the invention
samples, compared to the control samples Lower crack growth rate
correlates with good durability and related characteristics for
numerous applications, including tire applications and the like. In
addition, it can be seen from a comparison of Tables 35 and 36 that
better Tan .delta..sub.max values are achieved by the invention
samples, that is, values which are lower than the values of the
control sample. Accordingly, improved performance is achieved by
the invention samples for numerous product applications including,
for example, tire applications and the like requiring low
hysteresis for correspondingly low rolling resistance.
[0246] The advantageous performance characteristics of the
elastomer composites of the invention are exemplified by the crack
growth rate of invention sample no. 16 comprising N234 carbon black
and corresponding test results for control samples nos. 273 to 288
shown graphically in FIG. 22. Specifically, FIG. 22 clearly
demonstrates a correlation between MW.sub.sol and crack growth rate
for the control samples, as well as the advantageous impact of
excellent macro-dispersion in the elastomer composites of the
present invention. It should be understood that the MW.sub.sol
values shown in FIGS. 22-24 and in Tables 33-36 are for the
masterbatch materials prior to cure. The molecular weight of the
cured material is understood to correlate well to the MW.sub.sol
value of the uncured masterbatch. The crack growth rate of the
control samples over an MW.sub.sol range of about
0.25.times.10.sup.6 to 0.6.times.10.sup.6 is seen to fit well along
a straight line correlation to MW.sub.sol. In contrast, the
invention sample no. 16 at MW.sub.sol 0.5.times.10.sup.6 has
significantly better (i.e., lower) crack growth rate than any of
the corresponding control samples, due to the better
macro-dispersion D (%) of the invention sample. This is further
established by the similar showing in FIG. 23, wherein the crack
growth rate of invention sample no. 9 comprising N326 carbon black
is seen to be significantly lower than that of any of the
corresponding control samples nos. 145 to 160, and is well below
the correlation line. Likewise in FIG. 24 the excellent
macro-dispersion of invention sample no. 10 is seen to result again
in a crack growth value which lies far below the correlation line
between crack growth rate and MW.sub.sol established by the
corresponding control samples nos. 177 to 192. In FIG. 25, the max
tan .delta. at 60.degree. C. is shown graphically to be better,
i.e., lower, for invention samples nos. 24 to 28 and invention
samples nos. 29 to 32 than for corresponding control samples nos.
444 to 450.
[0247] The superior crack growth results discussed above for
elastomer composites of the present invention not only demonstrates
advantageous fatigue properties, but also indicates advantageous
fracture properties, such as excellent tear and cut-and-chip
resistance. The superior hysteresis results discussed above for the
elastomer composites of this invention not only demonstrate
advantageously low rolling resistance (and correspondingly higher
fuel economy) for motor vehicle tire applications, but also
indicates advantageous improvement in related performance
properties, such as reduced heat build-up. One or more of these
superior properties, fatigue and fracture resistance, low
hysteresis, low heat build-up, etc., render elastomer composites of
the present invention well suited for use in commercial
applications such as tire applications and in industrial rubber
products. Regarding tire applications, various preferred
embodiments of the invention are particularly well-suited for use
as: tire tread, especially in tread for radial and bias truck
tires, off-the-road ("OTR") tires, airplane tires and the like;
sub-tread; wire skim; sidewalls; cushion gum for retread tires; and
similar tire applications. The superior performance characteristics
achieve by various preferred embodiments of the invention can
provide improved tire durability, tread life and casing life,
better fuel economy for the motor vehicle and other advantages.
Regarding industrial rubber products, various preferred embodiments
of the invention are particularly well-suited for use as: engine
mounts, hydro-mounts, bridge bearings and seismic isolators, tank
tracks or tread, mining belts and similar products applications.
The superior performance characteristics achieved by various
preferred embodiments of the invention can provide improved fatigue
life, durability and other advantages for such product
applications.
[0248] FIGS. 26-29 are graphical representations of carbon black
morphology, structure (DBPA) and surface area (CTAB), corresponding
generally to FIG. 8. Carbon black morphology region 261 in FIG. 26
includes carbon blacks currently in commercial use for OTR tire
tread applications. Arrow 262 indicates the direction in which
region 261 can be advantageously extended in accordance with the
present invention. Performance characteristics such as cut-and-chip
resistance, crack growth resistance and tear resistance are
understood to improve generally in the direction of trend arrow 262
subject, however, in the past, to offsetting degradation of these
and other characteristics due to reduced molecular weight of the
natural rubber and/or poorer macro-dispersion resulting from the
use of such higher surface area, lower structure carbon blacks.
Elastomer composites of the present invention can employ such lower
structure, higher surface area carbon black indicated by trend
arrow 262 to achieve significantly improved OTR trend materials, in
view of their excellent macro-dispersion and MW.sub.sol.
[0249] Similarly, carbon black morphology region 271 in FIG. 27
includes carbon blacks currently in commercial use for truck and
bus (T/B) tire tread applications. Arrow 272 indicates the
direction in which region 271 can be advantageously extended in
accordance with the present invention. Performance characteristics,
such as wear resistance, are understood to improve generally in the
direction of trend arrow 272 subject, however, in the past, to
offsetting degradation of these and other characteristics due to
reduced molecular weight of the rubber and/or poorer
macro-dispersion resulting from use of such higher surface area
carbon blacks. Elastomer composites of the present invention can
employ such higher surface area carbon blacks indicated by trend
arrow 272 to achieve improved T/B tread materials, in view of their
excellent macro-dispersion and MW.sub.sol.
[0250] Similarly, carbon black morphology regions 281 and 283 in
FIG. 28 show carbon blacks currently in commercial use for tread
base and passenger car (PC) tire tread, respectively. Trend arrows
282 and 284 indicate the direction in which region 281 and 283,
respectively, can be advantageously extended in accordance with the
present invention. Performance characteristics such as heat
build-up (HBU) and rolling resistance are understood to improve for
tread base in the direction of trend arrow 282 subject, however, in
the past, to offsetting degradation of these and other
characteristics due to reduced molecular weight of the rubber
and/or poorer macro-dispersion resulting from use of such higher
surface area, lower structure carbon blacks. Likewise, performance
characteristics such as rolling resistance are understood to
improve for PC tread in the direction of trend arrow 284 subject,
however, in the past, to offsetting degradation of these and other
characteristics due to reduced molecular weight of the rubber
and/or poorer macro-dispersion resulting from use of such higher
surface area, lower structure carbon blacks. Elastomer composites
of the present invention can employ higher surface area, lower
structure carbon blacks indicated by arrows 282 and 284 to achieve
improved tread base and PC tread, respectively, in view of the
excellent macro-dispersion and the optional preservation of high
molecular weight in such elastomer composites.
[0251] Similarly, carbon black morphology regions 291, 293 and 294
in FIG. 29 show carbon blacks currently in commercial use for
sidewall, apex and steel belt tire applications, respectively.
Trend arrows 292 and 295 indicate the direction in which region 291
and 294, respectively, can be advantageously extended in accordance
with the present invention. Performance characteristics such as
heat build-up (HBU) and fatigue life are understood to improve for
sidewall in the direction of trend arrow 292 subject, however, in
the past, the offsetting degradation of these and other
characteristics due to reduced molecular weight of the rubber
and/or poorer macro-dispersion resulting from use of such lower
structure carbon blacks. Likewise, performance characteristics such
as heat buildup, processing and wire adhesion are understood to
improve for steel belt elastomeric materials in the direction of
trend arrow 295 subject, however, in the past, to offsetting
degradation of these and other characteristics due to reduced
molecular weight of the rubber and/or poorer macro-dispersion
resulting from use of such higher surface area, lower structure
carbon blacks. Elastomer composites of the present invention can
employ higher surface area and/or lower structure carbon blacks as
indicated by arrows 292 and 295 to achieve improved sidewall and
steel belt rubber materials, respectively, in view of the excellent
macro-dispersion and the optional preservation of high molecular
weight in such elastomer composites.
[0252] Additional Examples: Preferred Embodiment and Control
Samples Comprising Other Fillers
[0253] Additional samples of elastomer composites in accordance
with certain preferred embodiments of the present invention, and
corresponding control samples, were prepared. A first group of
these employed a multiphase aggregate filler of the type referred
to above as a silicon-treated carbon black.
[0254] Specifically, invention samples nos. 33-34 employed
ECOBLACK.RTM. silicon-treated carbon black commercially available
from Cabot Corporation (Billerica, Mass.). Such ECOBLACK.RTM.
filler has morphological properties, i.e., structure and surface
area, similar to that of carbon black N234. Sample no. 33 employed
45 phr ECOBLACK.RTM. filler and no extender oil. Sample no. 34
employed 68 phr ECOBLACK.RTM. filler and no extender oil. Typical
filler and extender oil usage for various product applications are
shown in Table 37, for elastomer composites of the invention
comprising natural rubber and a blend of carbon black and silica
filler. It should be understood that the use of silica filler in
the compositions shown in Table 37 would typically replace a like
amount of the carbon black filler.
60TABLE 37 Typical NR Formulations for Tire Applications Carbon
Carbon Black Silica Application Black Type Loading Oil Loading
Loading Truck/Bus N110, N115, 40-60 phr 0-20 phr 0-10 phr Tread
N121, N134, N220, N299 OTR Tread N110, N115, 45-55 phr 5-10 phr
5-20 phr N220, N231 Steel Belt N326 50-75 phr 0-5 phr 0-20 phr
Truck/Bus N330, N550 40-60 phr 0-20 phr Tread Base Carcass Ply
N326, N330, 40-60 phr 5-30 phr N550 Sidewall N330, N351, 60-60 phr
5-30 phr N550 Apex N326, N330, 50-90 phr 0-20 phr N351 LRR PC Tread
N234, N299, 40-60 phr 0-30 phr N339, N343, N347, N351
[0255] A second group of samples employed a blend or mixture of
silica and carbon black. In embodiments of the present invention
employing a blend of carbon black and silica fillers, it is
generally preferred that they be used in weight ratio of at least
about 60:40. That is, the carbon black preferably comprises at
least about 60 weight percent of the filler to achieve good
coagulation of the elastomer and to reduce or eliminate
reagglomeration of the silica in the masterbatch. In particular, in
examples nos. 35-38, as shown in Table 40, carbon black is used
together with particulate SiO.sub.2 filler HiSil.RTM. 233 available
from PPG Industries (Pittsburgh, Pa., USA), having surface area BET
of 150 m.sup.2/g, surface area DBPA of 190 mils/100 g, pH of 7 and
a primary particulate size of 19 nanometers.
[0256] All of the invention samples, i.e., additional invention
samples nos. 33-38, were prepared in accordance with the procedures
and apparatus used for invention samples 1-32, as described above.
Process and apparatus details for each of invention samples nos.
33-38 is given in Table 38, below. The field latex or concentrate
employed in samples nos. 33-38, as the case may be, is the same as
described above with reference to Table 24. It will be appreciated
that the data in Table 38 parallels that provided in Table 25,
above, for invention samples nos. 1-32. The carbon black filler
"CRX2000" listed in Table 38 is the ECOBLACK.RTM. silicon-treated
carbon black described above.
61TABLE 38 Invention Sample Production Details Cabot Elastomer
Composite Slurry Nozzle Tip CB Slurry Invention Carbon Black HiSil
233 Oil loading Dia. Land Length CB conc. Sample No. Latex type
Type Loading (phr) Loading (phr) (phr) (in) (in) (% wt) 33 field
latex CRX2000 46 0 0 0.020 0.5 14.5 34 field latex CRX2000 58 0 0
0.020 0.5 14.5 35 field latex N220 43 10 5 0.025 0.5 13.9 36 field
latex N234 41 9 0 0.020 0.5 13.5 37 field latex N234 31 20 0 0.020
0.5 14.0 38 latex concentrate STERLING 6740 29 20 0 0.020 0.5 15.5
Caogulum Zone Invention 1st portion 2nd portion 3rd portion 4th
portion Sample No. Dia. (in) Length (in) Dia. (in) Length (in) Dia.
(in) Length (in) Dia. (in) Length (in) 33 0.19 3.0 0.27 1.6 0.38
2.3 0.53 3.2 34 0.19 3.0 0.27 1.6 0.38 2.3 0.53 3.2 35 0.19 3.0
0.27 1.6 0.38 2.3 0.53 3.2 36 0.19 3.0 0.27 1.6 0.38 2.3 0.53 3.2
37 0.19 3.0 0.27 1.6 0.38 2.3 0.53 3.2 38 0.19 3.0 0.27 1.6 0.38
2.3 0.53 3.2 Mixing Zone MicroFluidizer Slurry Invention flow rate
Slurry velocity Antioxidant Latex flow rate Latex velocity Inlet
pressure Outlet pressure Sample No. (lb/min) (ft/sec) TNPP (phr)
Santoflex(phr) (lbs/min) (ft/sec) (psi) (psi) 33 6.2 710 0.3 0.4
Field 7.4 10.7 17000 34 6.2 710 0.3 0.4 Field 5.8 8.3 17000 35 5.2
380 0.3 0.4 Field 4.9 7.1 14500 36 5.0 576 0.3 0.4 Field 4.3 6.2
10000 37 4.8 550 0.3 0.4 Field 4.1 5.9 9500 38 5.1 580 0.3 0.4 Conc
2.2 3.2 9000 Slurry Nozzle Dewatering Drying and Cooling Production
Invention Tip Pressure Initial crumb Final crumb Product Product
Mixer Rate Invention Sample No. (psi) moisture (%) moisture (%)
temp. (.degree. F.) moisture (%) Type (lb/hr) Sample No. 33 -- 77.5
>8.0 435 0.2 T-block 66 33 34 -- 78.0 1.6 470 0.3 T-block 52 34
35 1650 77.9 >4.0 360 0.4 T-block 54 35 36 3000 79.2 1.0 475 0.5
T-block 39 36 37 2930 78.9 12.3 435 0.4 T-block 34 37 38 2600 69.7
4.2 455 0.2 T-block 48 38
[0257] The control samples 451-498 were prepared in accordance with
the procedures and apparatus described above for control samples
nos. 1-450. The processing code (see Table 13 above), filler
loading, rubber, MW.sub.sol and macro-dispersion for masterbatches
451-466 are set forth below in Table 39. The processing code,
filler loading, rubber, MW.sub.sol and macro-dispersion values of
the invention samples nos. 33-38 (along with the filler and oil
loadings for convenient reference) are shown in Table 40. It will
be seen from Table 39 that control samples 451-466 correspond in
composition to invention samples nos. 33 and 34. Similarly, control
samples nos. 467-498 correspond to invention samples nos.
35-38.
62 TABLE 39 CRX 2000/44/0 CRX 2000/58/0 RSS1 RSS1 Sample Mw.sub.sel
Sample Mw.sub.sel Code No. (K) D (%) No. (K) D (%) M2 909 909 M3
590 590 M2D1 451 461 3.48 459 333 8.61 M2D2 452 474 3.68 460 392
5.71 M2D3 453 489 7.17 461 388 9.48 M2D4 454 515 6.28 462 394 8.05
M3D1 455 393 2.89 463 280 2.23 M3D2 456 422 2.87 464 298 2.13 M3D3
457 435 4.15 465 350 4.05 M3D4 458 449 3.23 466 379 7.22
[0258]
63TABLE 10 Sol Molecular Weight and Undispersed Area of Invention
Samples Invention Sample No. CB/Loading/Oil Mw.sub.sol(K) D (%) 33
CRX 2000/44/0 380 0.18 34 CRX 2000/58/0 448 0.10 35 N220/Hilsil
233/43/10/5 500 0.14 36 N234/Hilsil 233/40/10/0 490 0.36 37
N234/Hilsil 233/30/20/0 399 0.23 38 STERLING 6740/Hilsil
233/30/20/0 354 0.39
[0259]
64 TABLE 41 RSS1 RSS1 Sample Mw.sub.sel Sample Mw.sub.sel Code No.
(K) D (%) No. (K) D (%) N220/HiisII 233/43/10/5 NHiisII 233/40/10/0
M2 803 909 M3 601 590 M2D1 467 493 1.51 475 443 8.74 M2D2 468 537
2.61 476 517 10.9 M2D3 469 523 2.82 477 569 12.5 M2D4 470 615 2.95
478 592 8.25 M3D1 471 417 0.95 479 358 6.65 M3D2 472 438 1.40 480
420 13.8 M3D3 473 433 2.15 481 516 13.9 M3D4 474 485 2.22 482 447
7.25 STERLING 6740/ N234/HiisII 233/30/20/0 HiisII 233/30/20/0 M2
909 909 M3 590 590 M2D1 483 394 4.37 491 430 3.77 M2D2 484 507 5.66
492 488 4.39 M2D3 485 526 4.7 493 517 5.37 M2D4 486 568 5.94 494
563 4.66 M3D1 487 377 8.39 495 375 3.5 M3D2 488 363 4.49 496 380
2.73 M3D3 489 376 5.07 497 419 2.72 M3D4 490 432 5.26 498 448
3.29
[0260] The excellent carbon black dispersion in the masterbatches
of invention samples 33-38 is demonstrated by comparison of the
macro-dispersion quality and MW.sub.sol values shown in Tables
39-41. The invention samples nos. 33-34 made with ECOBLACK.RTM.
silicon-treated carbon black, and the corresponding control samples
are compared in the semi-log plot of FIG. 30. Excellent carbon
black dispersion is seen in FIG. 30 for the invention samples,
representing preferred embodiments of elastomer composites in
accordance with the present disclosure. The invention samples
advantageously are below line 301 in FIG. 30, whereas all of the
control samples have poorer dispersion, being above line 301. In
fact, the preferred embodiments shown in FIG. 30 fall below a D (%)
value of 0.2% even at an MW.sub.sol value advantageously exceeding
0.4.times.10.sup.6. The data shown in FIG. 30 clearly reveals that
the macro-dispersion quality of the novel elastomer composites,
disclosed here, comprising silicon-treated carbon black is
significantly superior to that achievable using comparable
ingredients in prior dry mixing methods. The macro-dispersion
values for the elastomer composites of the invention shown in FIG.
30 are described by the following equations:
D(%)<1.0% (25)
[0261] when MW.sub.sol is less than 0.4.times.10.sup.6; and
log (D)<log
(1.0)+2.0.times.[MW.sub.sol-(0.4.times.10.sup.6)].times.10.- sup.-6
(26)
[0262] when
0.4.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6
[0263] It will be recognized that D (%) is the percent undispersed
area measured for defects greater than 10 microns and 1% is the
threshold macro-dispersion quality for the masterbatches in
accordance with these preferred embodiments of the present
invention. That is, none of the dry masticated masterbatches
achieved macro-dispersion quality of 1.0% or better at any
MW.sub.sol, even after dry mixing sufficiently to degrade
MW.sub.sol below 0.4.times.10.sup.6. The preferred embodiments
shown in FIG. 30 fall well below the threshold. It can be seen that
the elastomer composites of the invention comprising
silicon-treated carbon black provide heretofore unachieved balance
between macro-dispersion quality and MW.sub.sol.
[0264] Invention samples nos. 35-38 comprising carbon black blended
with silica filler and corresponding control samples are compared
in the semi-log plot of FIG. 31. Specifically, FIG. 31 shows the
macro-dispersion values and MW.sub.sol values of the invention
samples nos. 35-38 and corresponding control samples nos. 467-498.
Excellent carbon black dispersion is seen in FIG. 31 for the
invention samples, representing preferred embodiment of elastomer
composites in accordance with the present disclosure. The invention
samples advantageously are below line 311 in FIG. 31, whereas all
of the control samples have poorer dispersion, being above line
311. In fact, all of the preferred embodiments shown in FIG. 31
fall below a D (%) value of 0.4%. The data shown in FIG. 31 clearly
reveals that the macro-dispersion quality of the novel elastomer
composites, disclosed here, comprising carbon black/silica blends
over a range of MW.sub.sol values, is significantly superior to
that achievable using comparable ingredients in prior dry
mastication mixing methods. The macro-dispersion values for the
elastomer composites of the invention shown in FIG. 31 are
described by the following equations:
D(%)<0.8% (27)
[0265] when MW.sub.sol is less than 0.5.times.10.sup.6; and
log (D)<log
(0.8)+2.2.times.[MW.sub.sol-(0.5.times.10.sup.6)].times.10.- sup.-6
(28)
[0266] when
0.5.times.10.sup.6<MW.sub.sol<1.1.times.10.sup.6
[0267] It will be recognized that D (%) is the percent undispersed
area measured for defects greater than 10 microns and 0.8% is the
threshold macro-dispersion quality for masterbatches in accordance
with these preferred embodiments of the present invention. That is,
none of the dry masticated masterbatches achieved macro-dispersion
quality of 0.8% or better at any MW.sub.sol, even after dry mixing
sufficiently to degrade MW.sub.sol below 0.4.times.10.sup.6. The
preferred embodiments shown in FIG. 31 fall well below the
threshold macro-dispersion value of 0.8%, and even below 0.4%. It
can be seen that the elastomer composites of the invention
comprising carbon black/silica blend filler provide heretofore
unachieved balance between macro-dispersion quality and
MW.sub.sol.
[0268] In view of the foregoing disclosure, it will be apparent to
those skilled in the art that various additions, modifications,
etc. can be made without departing from the true scope and spirit
of the invention. All such additions and modifications are intended
to be covered by the following claims.
* * * * *