Methods of making an elastomer composite reinforced with silica and carbon black and products containing same

A method of producing a silica elastomer composite, comprising:

• providing a first fluid comprising a destabilized dispersion of silica with silica present in an amount of from 6 to 35 weight percent, and said first fluid having a first fluid volumetric flow rate, and providing a second fluid comprising an elastomer latex and said second fluid having a second fluid volumetric flow rate, and combining under continuous flow conditions at least the first fluid and the second fluid to form a semi-solid silica-containing continuous rubber phase mixture, and forming said semi-solid silica-containing continuous rubber phase mixture into said silica elastomer composite in a mixing chamber of a device, and recovering said silica elastomer composite having a silica content of about 15 phr to about 180 phr,
• wherein said at least one first fluid is provided as:
• i) two streams with one stream comprising a dispersion comprising carbon black and the other stream comprising said destabilized dispersion of silica;
• or
• ii) a single stream comprising a dispersion comprising carbon black and said destabilized dispersion of silica;
• or
• iii) a single stream of the destabilized dispersion of silica that includes carbon black.

A method of producing a silica elastomer composite, comprising:

• (a) providing a continuous flow of at least a first fluid comprising a destabilized dispersion of silica and a continuous flow of at least a second fluid comprising elastomer latex;
• (b) providing volumetric flow of the first fluid relative to that of the second fluid to yield a silica content of about 15 phr to about 180 phr in the silica elastomer composite;
• (c) providing a continuous flow of fluidized carbon black in dry form,
• (d) combining the first fluid flow and the second fluid flow, and said carbon black and in a mixing chamber of a device distributing the silica and carbon black within the elastomer latex to obtain a flow of a solid silica-carbon black-containing continuous rubber phase or semi-solid silica-carbon black-containing continuous rubber phase,
• wherein said flow of fluidized carbon black is combined with said first fluid before step d, or combined with said second fluid before step d, or added in step d.