Elastomeric compositions comprising reclaimed vulcanized elastomer particles of broad size distribution and chemically modified vulcanized elastomer particles
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.
1. A micronized elastomer powder formulation for use in manufacturing a vulcanized elastomer product, comprising:
a plurality of cured elastomer particles, wherein the plurality of cured elastomer particles comprise at least 1% by weight particles of size greater than or equal to 50 mesh, and wherein the plurality of cured elastomer particles comprise at least 20% by weight particles of size less than or equal to 140 mesh.
2. The micronized elastomer powder formulation of claim 1 , wherein the plurality of cured elastomer particles comprise a plurality of cured rubber particles.
3. The micronized elastomer powder formulation of claim 1 , further comprising uncured elastomer material.
4. The micronized elastomer powder formulation of claim 3 , wherein the uncured elastomer material comprises styrene butadiene, polybutadiene, natural rubber, nitrile rubber, butyl rubber, and combinations thereof.
5. The micronized elastomer powder formulation of claim 1 , further comprising a crosslinking agent.
6. The micronized elastomer powder formulation of claim 1 , wherein the crosslinking agent is sulfur.
7. The micronized elastomer powder formulation of claim 1 , further comprising filler material.
8. The micronized elastomer powder formulation of claim 7 , wherein the filler material comprises carbon black, silica, or a combination thereof.
9. The micronized elastomer powder formulation of claim 1 , further comprising one or more accelerators.
10. The micronized elastomer powder formulation of claim 9 , wherein the one or more accelerators are selected from the group comprising: N-tert-Butyl-2-benzothiazolesulfenamide (TBBS), 1,3-Diphenylguanine (DPG), and combinations thereof.
11. The micronized elastomer powder formulation of claim 1 , wherein the plurality of cured elastomer particles comprises at least 0.1% by weight particles of size greater than or equal to 40 mesh.
12. The micronized elastomer powder formulation of claim 1 , wherein the plurality of cured elastomer particles comprises at least 30% by weight particles of size less than or equal to 140 mesh.
13. The micronized elastomer powder formulation of claim 1 , wherein the plurality of cured elastomer particles comprises at least 10% by weight particles of size greater than or equal to 60 mesh.
14. The micronized elastomer powder formulation of claim 1 , wherein the plurality of elastomer rubber particles comprises at least 5% by weight particles of size greater than or equal to 60 mesh.
15. The micronized elastomer powder formulation of claim 1 , wherein the plurality of cured elastomer particles comprises at least 15% by weight particles of size greater than or equal to 80 mesh.
16. The micronized elastomer powder formulation of claim 1 , further comprising a plurality of chemically modified cured elastomer particles.
17. The micronized elastomer powder formulation of claim 16 , wherein the micronized elastomer powder formulation comprises between about 3%-6% by weight cured elastomer particles and about 3%-12% by weight chemically modified cured elastomer particles.
18. The micronized elastomer powder formulation of claim 16 , wherein a chemical modification of the plurality of chemically modified cured elastomer particles aids in crosslinking of the particles.
19. The micronized elastomer powder formulation of claim 1 , wherein the plurality of cured elastomer particles are produced via a cryogenic grinding process.
20. An elastomer composition for use in manufacturing a cured elastomer product, comprising
reclaimed elastomer particles having a particle size distribution defined by:
at least 9% by weight 60 mesh or larger particles;
at least 21% by weight 80 mesh or larger particles;
at least 38% by weight 120 mesh or larger particles;
at least 12% by weight 140 mesh or larger particles; and
at least 20% by weight particles smaller than 140 mesh.
21. The elastomer composition of claim 20 , wherein the elastomer comprises rubber.
22. The elastomer composition of claim 20 , further comprising uncured elastomer material.
23. The elastomer composition of claim 20 , further comprising a crosslinking agent.
24. The elastomer composition of claim 20 , further comprising filler material.
25. The elastomer composition of claim 20 , wherein the reclaimed elastomer particles further comprise at least a trace amount by weight of particles size 40 mesh or larger.
26. The elastomer composition of claim 20 , further comprising chemically modified vulcanized elastomer particles.
27. The elastomer composition of claim 26 , wherein the elastomer composition comprises between about 3%-6% by weight reclaimed elastomer particles and about 3%-12% by weight chemically modified vulcanized elastomer particles.
28. The elastomer composition of claim 26 , wherein a chemical modification of the chemically modified vulcanized elastomer particles aids in crosslinking of the particles.
29. The elastomer composition of claim 20 , wherein the reclaimed elastomer particles are produced via a cryogenic grinding process.
30. The elastomer composition of claim 20 , wherein the cured elastomer product is a vehicle tire.
31. An elastomeric composition, comprising:
uncured elastomer material;
a crosslinking agent; and
between about 3%-8% by composition weight reclaimed elastomer particles, wherein the reclaimed elastomer particles comprise at least 1% by weight particles of size 50 mesh or larger, and wherein the reclaimed elastomer particles comprise at least 20% by weight particles of size 140 mesh or smaller.
32. The elastomeric composition of claim 31 , wherein the reclaimed elastomer particles comprise reclaimed cured rubber particles.
33. The elastomeric composition of claim 31 , further comprising filler material.
34. The elastomeric composition of claim 31 , wherein the reclaimed elastomer particles comprise at least a trace amount by weight of particles size 40 mesh or larger.
35. The elastomeric composition of claim 31 , wherein the reclaimed elastomer particles comprise at least 30% by weight particles of size 140 mesh or smaller.
36. The elastomeric composition of claim 31 , wherein the reclaimed elastomer particles comprise at least 10% by weight particles of size 60 mesh or larger.
37. The elastomeric composition of claim 31 , further comprising chemically modified vulcanized elastomer particles.
38. The elastomeric composition of claim 37 , wherein the elastomeric composition comprises between about 3%-12% by weight chemically modified vulcanized elastomer particles.
39. The elastomer composition of claim 37 , wherein a chemical modification of the chemically modified vulcanized elastomer particles aids in crosslinking of the particles.
40. The elastomeric composition of claim 31 , wherein the reclaimed elastomer particles are produced via a cryogenic grinding process.