# US 2013/0158164 A1 · Elastomer composite with silica-containing filler and methods to produce same

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- Number: US 2013/0158164 A1
- Document ID: US20130158164A1
- Status: Published application
- Kind: A1
- Application number: 13/820,332
- Filed: 2011-09-14
- Published: 2013-06-20
- Earliest claimed: 2010-09-15
- Assignees: Cabot Corporation
- Inventors: Michael D. Morris; Anand Prakash; Frederick H. Rumpf
- Web page: https://patentgrep.com/patent/US20130158164A1

## CPC

- B29B 7/465: {each shaft comprising rotor parts of the Banbury type in addition to screw parts}
- B29B 7/7495: {for mixing rubber}
- B29B 7/842: {Removing liquids in liquid form}
- B29B 7/90: Fillers or reinforcements {, e.g. fibres}
- B29C 48/287: {Raw material pre-treatment while feeding (B29C48/78 takes precedence)}
- B29C 48/29: in liquid form
- B29C 48/297: {at several locations, e.g. using several hoppers or using a separate additive feeding}
- B29C 48/397: {using a single screw}
- B29C 48/40: using two or more parallel screws {or at least two parallel non-intermeshing screws}, e.g. twin screw extruders
- B29C 48/405: Intermeshing co-rotating screws
- B29C 48/465: using rollers
- B29C 48/57: provided with kneading disc-like elements, e.g. with oval-shaped elements
- B29C 48/682: {for twin screws}
- C08C 1/14: Coagulation
- C08J 3/215: at least one additive being also premixed with a liquid phase
- C08J 3/22: using masterbatch techniques
- C08K 5/005: {Stabilisers against oxidation, heat, light, ozone}
- C08K 5/548: containing sulfur {(C08K5/5477 takes precedence)}
- C08K 9/02: Ingredients treated with inorganic substances
- C08K 9/06: with silicon-containing compounds
- B29B 9/12: characterised by structure or composition
- B29C 2948/92704: Temperature
- B29C 2948/92885: Screw or gear
- B29C 2948/92895: Barrel or housing
- C08J 2321/02: Latex
- C08K 3/36: Silica
- B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- C08C: TREATMENT OR CHEMICAL MODIFICATION OF RUBBERS
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)

## Abstract

An elastomer composite with silica-containing filler is described, along with methods to make the same. The advantages achieved with the elastomer composite and methods are further described.

## Claims

### Claim 1

A method of producing an elastomer composite, comprising:
feeding a continuous flow of a first fluid comprising elastomer latex to a mixing zone of a coagulum reactor;
feeding a continuous flow of a second fluid comprising particulate silica-containing filler under pressure to the mixing zone of the coagulum reactor to form a mixture with the elastomer latex, the feeding of the second fluid against the first fluid within the coagulum reactor being sufficiently energetic to coagulate at least a portion of the elastomer latex as the elastomer latex is mixed with the particulate silica-containing filler in the coagulum reactor;
and further comprising introducing at least one coupling agent and introducing at least one further additive, such that the particulate silica-containing filler contacts the coupling agent prior to the silica-containing filler contacting the further additive, and wherein the coupling agent is introduced in the mixing zone or after the mixture exits the mixing zone.

### Claim 2

A method of producing an elastomer composite, comprising:
feeding a continuous flow of a first fluid comprising elastomer latex to a coagulum reactor;
feeding a continuous flow of a second fluid comprising particulate filler selected from silicon-treated carbon black, silica coated carbon black, or a mixture of both under pressure to the coagulum reactor to form a mixture with the elastomer latex, the feeding of the second fluid against the first fluid within the coagulum reactor being sufficiently energetic to coagulate at least a portion of the elastomer latex as the elastomer latex is mixed with the particulate silica-containing filler in the coagulum reactor;
and further comprising introducing at least one coupling agent and introducing at least one further additive, such that the particulate filler contacts the coupling agent prior to the particulate filler contacting the further additive.

### Claim 3 (depends on 2)

The method of claim 2, wherein the coupling agent is introduced to the second fluid at any point prior to feeding the second fluid to the coagulum reactor.

### Claim 4 (depends on 2)

The method of claim 2, wherein the coupling agent is introduced to the second fluid at any point prior to the coagulum reactor and the further additive is introduced to the first fluid at any point prior to the coagulum reactor.

### Claim 5 (depends on 1)

The method of claim 1, wherein the coupling agent is introduced to the mixture in coagulum reactor.

### Claim 6 (depends on 1)

The method of claim 1, wherein the coupling agent is introduced to the mixture after the mixture exits the coagulum reactor.

### Claim 7 (depends on 1)

The method of claim 1, further comprising conducting one or more processing steps after the elastomer composite exits the coagulum reactor.

### Claim 8 (depends on 7)

The method of claim 7, wherein the processing steps comprise at least one of:
a) dewatering the mixture to obtain a dewatered mixture;
b) mixing or compounding the dewatered mixture to obtain a compounded mixture;
c) milling the compounded mixture to obtain a milled mixture;
d) granulating or mixing the milled mixture;
e) baling the mixture after the granulating or mixing to obtain a baled mixture; and
f) optionally breaking apart the baled mixture and mixing.

### Claim 9 (depends on 8)

The method of claim 8, wherein the coupling agent is introduced just prior to and/or during one or more of the steps a) to f).

### Claim 10 (depends on 1)

The method of claim 1, wherein the silica-containing filler is silicon-treated carbon black, silica coated carbon black, precipitated silica, fumed silica, or any combinations thereof.

### Claim 11

(canceled)

### Claim 12 (depends on 1)

The method of claim 1, wherein the further additive comprises an antioxidant.

### Claim 13 (depends on 1)

The method of claim 1, further comprising discharging a substantially continuous flow of the elastomer composite from the coagulum reactor.

### Claim 14

(canceled)

### Claim 15 (depends on 7)

The method of claim 7, wherein the further additive is introduced in the one or more post processing steps.

### Claim 16 (depends on 1)

The method of claim 1, further comprising dry mixing the elastomer composite with additional elastomer to form an elastomer composite blend

### Claim 17

A method of producing an elastomer composite, comprising:
feeding a continuous flow of first fluid comprising elastomer latex to a coagulum reactor;
feeding a continuous flow of a second fluid comprising particulate silica-containing filler under pressure to the coagulum reactor to form a mixture with the elastomer latex, the feeding of the second fluid against the first fluid within the coagulum reactor being sufficiently energetic to coagulate at least a portion of the elastomer latex as the elastomer latex is mixed with the particulate silica-containing filler in the coagulum reactor;
and further comprising introducing at least one coupling agent and introducing at least one further additive in the method, wherein the coupling agent and the further additive are introduced at about the same time and wherein the elastomer latex is introduced as a single stage addition or a multi-stage addition.

### Claim 18

(canceled)

### Claim 19 (depends on 17)

The method of claim 17, wherein the coupling agent and further additive are introduced to the second fluid at any point prior to feeding the second fluid to the coagulum reactor.

### Claim 20 (depends on 17)

The method of claim 17, wherein the coupling agent and further additive are introduced to the first fluid at any point prior to the coagulum reactor.

### Claim 21 (depends on 17)

The method of claim 17, wherein the coupling agent and further additive are introduced to the mixture in the coagulum reactor.

### Claim 22 (depends on 17)

The method of claim 17, wherein the coupling agent and further additive are introduced to the mixture after the mixture exits the coagulum reactor.

### Claim 23 (depends on 17)

The method of claim 17, further comprising conducting one or more processing steps after the elastomer composite exits the coagulum reactor.

### Claim 24 (depends on 23)

The method of claim 23, wherein the processing steps comprise at least one of:
a) dewatering the mixture to obtain a dewatered mixture;
b) mixing or compounding the dewatered mixture to obtain a compounded mixture;
c) milling the compounded mixture to obtain a milled mixture;
d) granulating or mixing the milled mixture;
e) baling the mixture after the granulating or mixing to obtain a baled mixture; and
f) optionally breaking apart the baled mixture and mixing.

### Claim 25 (depends on 24)

The method of claim 24, wherein the coupling agent is introduced just prior to and/or during one or more of the steps a) to f).

### Claim 26 (depends on 17)

The method of claim 17, wherein the silica-containing filler is silicon-treated carbon black, silica coated carbon black, precipitated silica, fumed silica, or any combinations thereof.

### Claim 27

(canceled)

### Claim 28 (depends on 17)

The method of claim 17, wherein the further additive comprises an antioxidant.

### Claim 29 (depends on 17)

The method of claim 17, further comprising discharging a substantially continuous flow of the elastomer composite from the coagulum reactor.

### Claim 30

(canceled)

### Claim 31 (depends on 23)

The method of claim 23, wherein the further additive is introduced in the one or more post processing steps.

### Claim 32 (depends on 17)

The method of claim 17, further comprising dry mixing the elastomer composite with additional elastomer to form an elastomer composite blend.

### Claim at position 33

33-58. (canceled)

### Claim 59 (depends on 7)

The method of claim 7, wherein the post processing steps comprise at least roll milling of the elastomer composite for a time sufficient to provide at least about 0.7 MJ/kg of specific energy to the elastomer composite.

### Claim 60

(canceled)

### Claim 61 (depends on 23)

The method of claim 23, wherein the post processing steps comprise at least roll milling of the elastomer composite for a time sufficient to provide at least about 0.7 MJ/kg of specific energy to the elastomer composite.

### Claim at position 37

62-64. (canceled)

### Claim 65 (depends on 2)

The method of claim 2, wherein the coupling agent is introduced to the mixture in coagulum reactor.

### Claim 66 (depends on 2)

The method of claim 2, wherein the coupling agent is introduced to the mixture after the mixture exits the coagulum reactor.

### Claim 67 (depends on 2)

The method of claim 2, further comprising conducting one or more processing steps after the elastomer composite exits the coagulum reactor.

### Claim 68 (depends on 67)

The method of claim 67, wherein the processing steps comprise at least one of:
a) dewatering the mixture to obtain a dewatered mixture;
b) mixing or compounding the dewatered mixture to obtain a compounded mixture;
c) milling the compounded mixture to obtain a milled mixture;
d) granulating or mixing the milled mixture;
e) baling the mixture after the granulating or mixing to obtain a baled mixture; and
f) optionally breaking apart the baled mixture and mixing.

### Claim 69 (depends on 68)

The method of claim 68, wherein the coupling agent is introduced just prior to and/or during one or more of the steps a) to f).

### Claim 70 (depends on 67)

The method of claim 67, wherein the further additive is introduced in the one or more post processing steps.

### Claim 71 (depends on 2)

The method of claim 2, wherein the further additive comprises an antioxidant.

### Claim 72 (depends on 2)

The method of claim 2, further comprising discharging a substantially continuous flow of the elastomer composite from the coagulum reactor.

### Claim 73 (depends on 2)

The method of claim 2, further comprising dry mixing the elastomer composite with additional elastomer to form an elastomer composite blend.