Lehigh Technologies, Inc.

Frank Papp

Charles Rosenmayer

Chad Aaron Jasiunas

Adel Farhan Halasa

Kedar D Murthy

Glenn Denstaedt

Alan Edward Barton

Alan Barton

Kedar Murthy

Elastomer compositions comprising uncured elastomer and reclaimed elastomer are described. In one embodiment, the compositions comprise reclaimed elastomer material (micronized rubber powder) of broad particle size distribution, which is less expensive than traditional reclaimed elastomer material with narrow particle size distribution. Further, compositions comprising reclaimed elastomer materials with broad particle size distribution perform comparably to those comprising reclaimed elastomer materials with narrow particle size distribution. In other embodiments, the compositions comprise both vulcanized and devulcanized elastomer materials. Advantageously, by using a combination of vulcanized and devulcanized material, it is possible to incorporate a greater percentage by weight of reclaimed material in to an elastomer composition, thus providing additional cost savings while maintaining high levels of mechanical properties. Further, the use of the reclaimed material reduces landfill waste resulting in a more environmentally friendly product.

Elastomeric compositions comprising reclaimed vulcanized elastomer particles of broad size distribution and chemically modified vulcanized elastomer particles

The renewed rubber of this invention can be used in rubber formulations that are used in manufacturing a wide array of rubber products, including tires, power transmission belts, conveyor belts, hoses, and a wide array of other products. The present invention more specifically discloses a method for manufacturing an environmentally friendly, chemically functionalized, renewed rubber composition having a highly desirable combination of physical properties and which exhibits excellent processability comprising the steps of (1) blending a micronized rubber powder with a processing aid and a chemical functionalizing agent to produce a blended mixture; (2) processing the blended mixture under conditions of high shear and low temperature to produce a reacted mixture; (3) adding a stabilizer to the reacted mixture to produce the chemically functionalized renewed rubber composition.

Chemically functionalized renewed rubber composition

This invention is based upon the discovery that micronized solution styrene-butadiene rubber from postconsumer sources can be included in rubber formulations without severely compromising abrasion resistance. The micronized solution styrene-butadiene rubber utilized in the rubber formulations of this invention can be made by cryogenic grinding postconsumer rubber products using conventional procedures. For instance, it can be made by cryogenically grinding a tire tread containing a high level of solution styrene-butadiene rubber. The micronized solution styrene-butadiene rubber can then be blending into desired virgin rubbers and cured without significantly compromising the abrasion resistance of the rubber formulation. The rubber formulation of this invention is comprised of a natural or synthetic rubber and from 1 weight percent to 30 weight percent of a micronized rubber composition containing at least 10 weight percent solution styrene-butadiene rubber and having a particle size of 40 mesh to 200 mesh.

Recycled micronized rubber formulation having improved abrasion resistance

Elastomer compositions comprising uncured elastomer and reclaimed elastomer are described. In one embodiment, the compositions comprise reclaimed elastomer material (micronized rubber powder) of broad particle size distribution, which is less expensive than traditional reclaimed elastomer material with narrow particle size distribution. Further, compositions comprising reclaimed elastomer materials with broad particle size distribution perform comparably to those comprising reclaimed elastomer materials with narrow particle size distribution. In other embodiments, the compositions comprise both vulcanized, and devulcanized elastomer materials. Advantageously, by using a combination of vulcanized and devulcanized material, it is possible to incorporate a greater percentage by weight of reclaimed material in to an elastomer composition, thus providing additional cost savings while maintaining high levels of mechanical properties. Further, the use of the reclaimed material reduces landfill waste resulting in a more environmentally friendly product.

This invention relates to certain rubber formulations which exhibit a low level of hysteresis which are comprised of a chemically functionalized renewed rubber and virgin solution styrene-butadiene rubber. These rubber formulations are loaded with a reinforcing silica. The rubber formulations of this invention can be utilized in making rubber products such as, tires, tracks, and conveyor belts which will promote energy savings by virtue of their low hysteretic properties. The present invention more specifically discloses a rubber composition which is comprised of (1) a solution styrene-butadiene rubber; (2) a functionalized renewed rubber composition which is comprised of an elastomeric polymer and a stabilizer; wherein the rubber composition has a crosslink density which is within the range of 0.05 to 2.0&#xd7;10mole/g, and wherein the rubber composition has a solubility fraction of less than 90 percent; and (3) a reinforcing filler including reinforcing silica.

A method of functionalizing reclaimed elastomer material is described. The method involves subjecting particles of the reclaimed elastomer material to shear at temperatures less than 100&#xb0; C. such that inter-chain bonds of the reclaimed elastomer material are cleaved wherein the particles of the reclaimed elastomer material have a size of 60 mesh or smaller. The reclaimed elastomer material can be subjected to shear in the presence of a modifier which selectively promotes the cleavage of inter-chain bonds in the reclaimed elastomer material. A functionalized reclaimed elastomer material made by a method as described above and an elastomer compound which comprises the functionalized reclaimed elastomer material are also described.

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Fort Mill, SC, United States of America

Frank Papp