Cabot Corporation

Other

Bin Chung

Ivan Zlatko Podobnik

Allan Clark Morgan

Melinda Ann Mabry

Frederick Harry Rumpf

Joseph Cianciolo

Malcolm John Andrews

Susan W Green

Scott Adrian Westveer

Bruce E MacKay

Ting Wang

Noboru Tokita

James A Shell

William L Sifleet

Mark A Wilkinson

Ronald C Hurst

David J Kaul

John M Branan, Jr

John M Funt

Frank J Hrach, Jr

Daniel W Weaver

Jay J Zimmer

Sergio A Montes

Ivan Z Podobnik

Elastomer masterbatch is processed in a continuous compounder having multiple parallel elongate rotors axially oriented in an elongate processing chamber. Optionally, additional materials are compounded into the masterbatch, e.g., additives, other elastomeric compositions, etc. Preferably, the masterbatch then is further processed in an open mill. Excellent control of Mooney Viscosity is achieved. In certain preferred embodiments, 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 coagulated 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 without need of adding acid or salt solution or other coagulation step. The coagulated elastomer and particulate filler composite is fed into the aforesaid continuous compounder for processing and control of its moisture level and Mooney Viscosity. Novel elastomer composites are produced. Such novel elastomer composites combine material properties and characteristics, such as choice of filler, elastomer, level of filler loading, moisture level, Mooney Viscosity, balance between molecular weight and amount of bound rubber, and macro-dispersion not previously achieved.

Methods and apparatus for producing and treating novel elastomer composites

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.

Elastomer composites, method and apparatus

Elastomer composite blends are produced by novel wet/dry mixing methods and apparatus. In the wet mixing step or stage, 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. The coagulum produced by such wet mixing step, with or without intermediate processing steps, is then mixed with additional elastomer in a dry mixing step or stage to form elastomer composite blends. The additional elastomer to the coagulum may be the same as or different from the elastomer(s) used in the wet mixing step.

Elastomer composite blends and methods-II

Method and apparatus for producing and treating novel elastomer composites

EPDM compositions comprising EPDM and specified carbon blacks which, when extruded or shaped, exhibit either a highly gloss or a textured matte finish. The carbon black is present in an amount of 100 to about 300, and more preferably about 150 to about 250, parts by weight per 100 parts by weight EPDM.

Carbon black containing EPDM compositions having either a high gloss or a textured matte finish

A process for producing carbon blacks comprised of mixing an oxidant, primary fuel, and carbon black feedstock to form carbon black particles and aggregates, passing the mixture through a reactor, cooling, separating, and recovering the carbon black product. The improvement comprises the addition of a secondary oxidant-containing stream to the reactor such that the secondary oxidant stream does not interfere with the formation of the carbon black particles and aggregates in the reactor. Also disclosed are new carbon black products defined by the following parameters:

Carbon blacks

Elastomer composite blends and methods - II

Elastomer composites method and apparatus

Elastomeric compositions 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 flowing 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. Semi-confined flow of the mixture in the coagulum zone is achieved preferably with progressively increasing cross-sectional dimension of the coagulum zone from the mixing zone to the discharge end. Highly efficient and effective elastomer coagulation can be achieved without the need for a coagulation step involving exposure to acid or salt solution or the like. In addition to elastomeric compositions comparable to those achievable using traditional acid or salt coagulation techniques, novel elastomeric compositions can be prepared employing previously unworkable fillers, such as carbon black of exceptionally high surface area and low structure, etc., and/or having heretofore unachievable performance properties, filler dispersion levels, elastomer molecular weight distribution or a combination of any of these.

Methods for producing elastomeric compositions

Disclosed are foamable EPDM compositions comprising EPDM, a carbon black having a CTAB of about 50 to 60 m2/g and DBP of 90 to 115 cc/100 g and a blowing agent which are advantageous for use in applications where UHF microwave curing is utilized and for replacing foamable EPDM compositions incorporating similar amounts of conventional blends of carbon blacks. Also disclosed are foamed, cured EPDM compositions comprising: EPDM and a carbon black having a CTAB of about 50 to 60 m2/g and DBP of 90 to 115 cc/100 g which have advantageously lower sponge density and lower sponge compression set than EPDM compositions incorporating similar amounts of conventional low reinforcing carbon blacks. Further disclosed is a process for producing the foamed, cured EPDM compositions of the present invention. Additionally disclosed is use of the foamed, cured EPDM compositions of the present invention as weatherstripping.

EPDM compositions and process for producing same

Carbon black containing EPDM compositions and process for producing same

Growing community of inventors

Nashua, NH, United States of America

Bin Chung