Novel elastomer composites, method and apparatus

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).

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.

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.

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.

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.

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.

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.

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).

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.

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.

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(%)≦0.2% (i)
• when MWsol≦0.45×106;
• and
• log (D)≦log (0.2)+2.0×(MWsol−0.45×106)×10−6 (ii)
• when 0.45×106<MWsol<1.1×106.

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 MWsol is less than 0.7×106;
• and
• log (D)<log 1.0+2.5×(MWsol−0.7×106)×104 (ii)
• when 0.7×106<MWsol<1.1×106.

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 MWsol is less than 0.35×106;
• and
• log (D)<log×(0.3)+2.8(MWsol−0.35×106)×106 (ii)
• when 0.35×106<MWsol<1.1×106.

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 MWsol is less than 0.35×106;
• and
• log (D)<log (0.1)+2.0×(MWsol−0.30×106)×10−6 (ii)
• when 0.3×106<MWsol<1.1×106.

An elastomer composite comprising natural rubber, 30 to 70 phr STERLING® 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 MWsol is less than 0.3×106;
• and
• log (D)<log (0.1)+2.0×(MWsol−0.3×106)×10−6 (ii)
• when 0.3×106<MWsol<1.1×106.

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 MWsol is less than 0.35×106;
• and
• log (D)<log×(0.3)+2.8(MWsol−0.35×106)×106 (ii)
• when 0.35×106<MWsol<1.1×106.

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 MWsol is less than 0.35×106;
• and
• log (D)<log (0.5)+2.5×(MWsol−0.35×106)×10−6 (ii)
• when 0.35×106<MWsol<1.1×106.

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 MWsol (weight average) is less than 0.7×106;
• and
• log (D)<log (1.0)+2.5×(MWsol−0.7×106)×10−6 (ii)
• when 0.7×106<MWsol<1.1×106.

An elastomer composite comprising natural rubber, 30 to 70 phr BLACK PEARL® 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 MWsol is less than 0.65×106;
• and
• log (D)<log (1.5)+2.5×(MWsol−0.65×106)×106 (ii)
• when 0.65×106<MWsol<1.1×106.

An elastomer composite comprising natural rubber, 30 to 70 phr REGAL® 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 MWsol is less than 0.6×106;
• and
• log (D)<log (1.0)+2.5×(MWsol−0.6×106)×10−6 (ii)
• when 0.6×106<MWsol<1.1×106.

An elastomer composite comprising natural rubber, 30 to 70 phr REGAL® 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 MWsol is less than 0.6×106;
• and
• log (D)<log (1.0)+2.5×(MWsol−0.6×106)×10−6 (ii)
• when 0.6×106<MWsol<1.1×106.

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 MWsol is less than 0.6×106;
• and
• log (D)<log (1.0)+2.5×(MWsol−0.6×106)×106 (ii)
• when 0.6×106<MWsol<1.1×106.

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 MWsol is less than 0.55×106;
• and
• log (D)<log (0.3)+2.0×(MWsol−0.55×106)×106 (ii)
• when 0.55×106<MWsol<1.1×106.

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 MWsol is less than 0.5×106;
• and
• log (D)<log (0.8)+2.2×(MWsol−0.5×106)×10−6 (ii)
• when 0.5×106<MWsol<1.1×106.

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 MWsol is less than 0.4×106;
• and
• log (D)<log (1.0)+2.0×(MWsol−0.4×106)×106 (ii)
• when 0.4×106<MWsol<1.1×106.

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.