Elastomer composite blends, method and apparatus for producing same

Abstract

A wet mix elastomer composite comprising carbon black dispersed in an elastomer including a blend of a natural rubber and styrene-butadiene rubber. When the wet mix elastomer composite is processed with CTV Method 1, the vulcanized wet mix elastomer composite exhibits a resistivity that A) has a natural logarithm satisfying the equation ln(resistivity)≧−0.1(loading)+x, where x is 14, or B) is at least 2.9 times greater than the resistivity of a vulcanized dry mix elastomer composite having the same composition and prepared using Comparative CTV Method 1.

1 . A wet mix elastomer composite comprising carbon black dispersed in elastomer, the elastomer comprising a blend of a natural rubber and styrene-butadiene rubber, wherein:
 when the wet mix elastomer composite is processed with CTV Method 1, the vulcanized wet mix elastomer composite exhibits a resistivity that A) has a natural logarithm satisfying the equation ln(resistivity)≧−0.1(loading)+x, where x is 14, or B) is at least 2.9 times greater than the resistivity of a vulcanized dry mix elastomer composite having the same composition and prepared using Comparative CTV Method 1.   
     
     
         2 . A vulcanized wet mix elastomer composite comprising carbon black dispersed in elastomer, the elastomer comprising a blend of a natural rubber and styrene-butadiene rubber, wherein the vulcanized wet mix elastomer composite exhibits a ratio of T300/T100 that is at least 18% greater than the same ratio for a vulcanized dry mix elastomer composite having the same composition as the vulcanized wet mix elastomer composite. 
     
     
         3 . The elastomer composite of  claim 1 , wherein the elastomer composite includes natural rubber and about 1 to about 36 wt % styrene-butadiene rubber with respect to the total rubber content. 
     
     
         4 . The elastomer composite of  claim 1 , wherein the elastomer composite includes natural rubber and about 20 to about 36 wt % styrene-butadiene rubber with respect to the total rubber content. 
     
     
         5 . The elastomer composite of  claim 1 , wherein the elastomer composite exhibits a macrodispersion of less than 0.1% undispersed area. 
     
     
         6 . A method for preparing an elastomer composite, comprising:
 feeding a continuous flow of a first fluid comprising a first elastomer latex to a mixing zone of a coagulum reactor;   feeding a continuous flow of a second fluid comprising a second elastomer latex to the mixing zone;   feeding a continuous flow of a third fluid comprising a particulate filler slurry to the mixing zone;   allowing the first elastomer latex and the second elastomer latex to coagulate with the particulate filler; and   discharging a flow of elastomer composite from a discharge end of the coagulum reactor.   
     
     
         7 . The method of  claim 6 , wherein the first elastomer latex comprises natural rubber latex. 
     
     
         8 . The method of  claim 6 , wherein the second elastomer latex comprises a synthetic elastomer latex. 
     
     
         9 . The method of  claim 6 , wherein, the particulate filler comprises carbon black. 
     
     
         10 . The method of  claim 6 , wherein the first fluid and the second fluid combine with the third fluid to form a mixture, and wherein the first fluid and the second fluid combine with the third fluid substantially simultaneously. 
     
     
         11 . An elastomer composite prepared by a method comprising:
 feeding a continuous flow of a first fluid comprising a first elastomer latex to a mixing zone of a coagulum reactor;   feeding a continuous flow of a second fluid comprising a second elastomer latex to the mixing zone;   feeding a continuous flow of a third fluid comprising a particulate filler slurry to the mixing zone;   allowing the first elastomer latex and the second elastomer latex to coagulate with the particulate filler; and   discharging a flow of elastomer composite from a discharge end of the coagulum reactor.   
     
     
         12 . The elastomer composite of  claim 11 , wherein the first elastomer latex comprises a natural rubber latex. 
     
     
         13 . The elastomer composite of  claim 11 , wherein the second elastomer latex comprises a synthetic elastomer latex. 
     
     
         14 . The elastomer composite of  claim 11 , wherein the particulate filler comprises carbon black. 
     
     
         15 . The elastomer composite of  claim 11 , wherein the first fluid and the second fluid combine with the third fluid to form a mixture, and wherein the first fluid and the second fluid combine with the third fluid substantially simultaneously. 
     
     
         16 . The elastomer composite of  claim 11 , wherein the first fluid and the third fluid combine to form a mixture, and wherein the second fluid combines with the mixture. 
     
     
         17 . The elastomer composite of  claim 11 , wherein the first elastomer latex and the second elastomer latex are incompatible. 
     
     
         18 . The elastomer composite of  claim 2 , wherein the elastomer composite includes natural rubber and about 1 to about 36 wt % styrene-butadiene rubber with respect to the total rubber content. 
     
     
         19 . The elastomer composite of  claim 2 , wherein the elastomer composite includes natural rubber and about 20 to about 36 wt % styrene-butadiene rubber with respect to the total rubber content. 
     
     
         20 . The elastomer composite of  claim 2 , wherein the elastomer, composite exhibits a macrodispersion of less than 0.1% undispersed area.