Functionalized silica with elastomer binder

1. A functionalized silica product, comprising particles of a hydrophobated silica having a coating of an emulsion polymer, wherein a weight ratio of the hydrophobated silica to the emulsion polymer is from about 12/1 to about 50/1, wherein the silica is hydrophobated by a silane, and the particles are loosely agglomerated in the form of one of a friable crumb and a powder.

2. The functionalized silica product of claim 1 , wherein the silane is selected from the group consisting of (3-mercaptopropyl)triethoxysilane, (3-mercaptopropyl)trimethoxysilane, (3-thiocyanatopropyl)trimethoxy silane, (3-thiocyanatopropyl)triethoxysilane, Bis[3-(triethoxysilyl)propyl]tetrasulfide, Bis[3-(trimethoxysilyl)propyl]tetrasulfide, Bis[3-(triethoxysilyl)propyl]disulfide, Bis[3-(trimethoxysilyl)propyl]disulfide, 3-(triethoxysilyl)propyl octanethioate, silanes that contain blocked mercaptan groups, and combinations thereof.

3. The functionalized silica product of claim 2 , wherein the silane is (3-mercaptopropyl)trimethoxysilane silane.

4. The functionalized silica product of claim 1 , wherein the emulsion polymer is selected from the group consisting of natural rubber, butadiene, isoprene, polymer made from a conjugated diene having from 4 to 12 carbon atoms with a vinyl substituted aromatic having from 8 to 12 carbon atoms, polychloroprene, copolymers of vinylidene fluoride and hexafluoropropylene, acrylic rubber, nitrile rubber, and combinations thereof.

5. The functionalized silica product of claim 4 , wherein the emulsion polymer is an emulsion styrene butadiene rubber.

6. A method for manufacturing a functionalized silica product, the method comprising the steps of:

admixing a silane solution and a silica slurry to form a hydrophobated silica slurry;

blending the hydrophobated silica slurry into an aqueous rubber latex to form a blended slurry;

coagulating the blended slurry to form a coagulated functionalized silica product;

dewatering the coagulated functionalized silica product; and

drying and breaking up the coagulated functionalized silica product to form particles of a hydrophobated silica having a coating of an emulsion polymer, wherein a weight ratio of the hydrophobated silica to the emulsion polymer is from about 4/1 to about 50/1 and the particles are loosely agglomerated in the form of one of a friable crumb and a powder,

wherein the emulsion polymer is selected from the group consisting of natural rubber, butadiene, isoprene, polymer made from a conjugated diene having from 4 to 12 carbon atoms with a vinyl substituted aromatic having from 8 to 12 carbon atoms, polychloroprene, copolymers of vinylidene fluoride and hexafluoropropylene, nitrile rubber, and combinations thereof.

7. The method of claim 6 , wherein the silica slurry is heated prior to the step of admixing the silane solution with the silica slurry.

8. A method for manufacturing a functionalized silica product, the method comprising the steps of:

admixing a silane solution and a silica slurry to form a hydrophobated silica slurry;

blending the hydrophobated silica slurry into an aqueous rubber latex to form a blended slurry;

coagulating the blended slurry to form a coagulated functionalized silica product;

dewatering the coagulated functionalized silica product; and

drying and breaking up the coagulated functionalized silica product to form particles of a hydrophobated silica having a coating of an emulsion polymer, wherein a weight ratio of the hydrophobated silica to the emulsion polymer is from about 4/1 to about 50/1, wherein a pH of the hydrophobated silica slurry is adjusted to a range from 7.0 to 9.5 by the addition of a basic solution prior to the step of blending the hydrophobated silica slurry into the aqueous rubber latex.

9. The method of claim 6 , wherein the step of drying and breaking up the coagulated functionalized silica product includes spray drying the coagulated functionalized silica product.

10. A rubber formulation, comprising:

a quantity of elastomer; and

a quantity of particles of a hydrophobated silica having a coating of an emulsion polymer different from the elastomer, wherein a weight ratio of the hydrophobated silica to the emulsion polymer is from about 12/1 to about 50/1, wherein the silica is hydrophobated by a silane,

the particles substantially evenly distributed throughout the elastomer.

11. The rubber formulation of claim 10 , wherein the quantity of elastomer includes a solution polymer.

12. An article comprising the rubber formulation of claim 10 .

13. A tire comprising a component with the rubber formulation of claim 10 .

14. The functionalized silica product of claim 1 , wherein the hydrophobated silica includes a high surface area silica having a specific surface greater than about 150 m 2 /g.