Carbon and elastomer integration
Compounds having an elastomer material, a filler material, at least one additive material, and at least one accelerant material are disclosed. In various embodiments, the filler material comprises a graphene-based carbon material. In various embodiments, the graphene-based carbon material comprises graphene comprising up to 15 layers, carbon aggregates having a median size from 1 to 50 microns, a surface area of the carbon aggregates at least 50 m 2 /g, when measured via a Brunauer-Emmett-Teller (BET) method with nitrogen as the adsorbate, and no seed particles.
1. A compound comprising:
an elastomer material;
a filler material;
at least one additive material; and
at least one accelerant material;
wherein the filler material comprises a graphene-based carbon material, wherein the graphene-based carbon material comprises:
carbon particles comprising graphene comprising up to 15 layers; and
particles of a nano-mix additive;
wherein:
the particles of the nano-mix additive are integrated with the carbon particles on a particle level such that the particles of the nano-mix additive and the carbon particles form aggregates together; and
the aggregates have a median size from 1 to 50 microns.
2. The compound of claim 1 , wherein the graphene-based carbon material comprises an electrical conductivity greater than 500 S/m when compressed and a surface area of the aggregates of at least 50 m 2 /g, when measured via a Brunauer-Emmett-Teller (BET) method with nitrogen as the adsorbate.
3. The compound of claim 1 , wherein the graphene-based carbon material further comprises at least one carbon allotrope other than the graphene, and a ratio of the graphene to the carbon allotrope other than graphene is from 1:100 to 10:1.
4. The compound of claim 3 , wherein the carbon allotrope other than graphene comprises multi-walled spherical fullerenes.
5. The compound of claim 1 , wherein the filler material further comprises silica, and a ratio of the silica to the graphene-based carbon material is from 10:1 to 1:1.
6. The compound of claim 1 , wherein the elastomer material is selected from the group consisting of natural rubber and synthetic rubber.
7. The compound of claim 1 , wherein the additive material comprises a material selected from the group consisting of: a silane coupling agent, an oil, a zinc oxide material, a stearic acid material, a wax material, a plasticizer, an antiozonant, an antioxidant, a viscosity modifier, and a sulfur cross-linker.
8. The compound of claim 1 , wherein the accelerant material comprises N-tert-butyl-2-benzothiazyl sulfonamide.
9. The compound of claim 1 , wherein the accelerant material comprises N-tert-butyl-2-benzothiazyl sulfonamide and diphenylguanidine, wherein a concentration of N-tert-butyl-2-benzothiazyl sulfonamide is higher than a concentration of diphenylguanidine.
10. The compound of claim 1 , wherein the graphene-based carbon material is a functionalized graphene-based carbon material.
11. The compound of claim 10 , wherein the functionalized graphene-based carbon material comprises a species selected from the group consisting of H, O, S, N, Si, aromatic hydrocarbons, Sr, F, I, Na, K, Mg, Ca, Cl, Br, Mn, Cr, Zn, B, Ga, Rb and Cs.
12. The compound of claim 1 , wherein a Phillips Dispersion Rating of the compound is from 6 to 10.
13. The compound of claim 1 , wherein a G′ storage modulus at −20° C. of the compound, as measured by ASTM D5992-96 (2011), is from 5 MPa to 12 MPa.
14. The compound of claim 1 , wherein a tan delta at −10° C. of the compound, as measured by ASTM D5992-96 (2011), is from 0.35 to 1.0.
15. The compound of claim 1 , wherein a tan delta at 0° C. of the compound, as measured by ASTM D5992-96 (2011), is from 0.3 to 0.6.
16. The compound of claim 1 , wherein a tan delta at 30° C. of the compound, as measured by ASTM D5992-96 (2011), is from 0.1 to 0.3.
17. The compound of claim 1 , wherein a G′ storage modulus at 30° C. of the compound, as measured by ASTM D5992-96 (2011), is from 1 MPa to 6 MPa.
18. The compound of claim 1 , wherein a J″ loss compliance at 30° C., as measured by ASTM D5992-96 (2011), is from 4E-8 1/Pa to 1E-7 1/Pa.
19. The compound of claim 1 , wherein a tan delta at 60° C. of the compound, as measured by ASTM D5992-96 (2011), is from 0.1 to 0.3.
20. The compound of claim 1 , wherein a G′ storage modulus at 60° C. of the compound, as measured by ASTM D5992-96 (2011), is from 1 MPa to 4 MPa.
21. The compound of claim 1 , wherein the particles of the nano-mix additive comprise interlayers of organic and inorganic materials.
22. The compound of claim 1 , wherein the particles of the nano-mix additive comprise silica.
23. The compound of claim 1 , wherein the particles of the nano-mix additive comprise silicon.
24. The compound of claim 1 , wherein the particles of the nano-mix additive comprise ZnO.
25. The compound of claim 1 , wherein the particles of the nano-mix additive comprise metals.
26. The compound of claim 1 , wherein the particles of the nano-mix additive and the carbon particles have average diameters less than 100 nm.
27. The compound of claim 1 , wherein:
the graphene-based carbon material is produced using a hydrocarbon cracking process;
the particles of the nano-mix additive are introduced during the hydrocarbon cracking process; and
the particles of the nano-mix additive are integrated with the carbon particles as the graphene-based carbon material is produced.
28. The compound of claim 1 , wherein:
the graphene-based carbon material is produced using a hydrocarbon cracking process;
a nano-mix additive material is introduced during the hydrocarbon cracking process;
the nano-mix additive material forms the particles of the nano-mix additive; and
the particles of the nano-mix additive are integrated with the carbon particles as the graphene-based carbon material is produced.
29. The compound of claim 28 , wherein the nano-mix additive material is introduced into the hydrocarbon cracking process as a gas, a liquid, or a colloidal dispersion.
30. A compound comprising:
an elastomer material;
a filler material;
at least one additive material; and
at least one accelerant material;
wherein:
the filler material comprises silica and a graphene-based carbon material, wherein the graphene-based carbon material comprises:
carbon particles comprising graphene comprising up to 15 layers; and
particles of a nano-mix additive;
wherein:
the particles of the nano-mix additive are integrated with the carbon particles on a particle level such that the particles of the nano-mix additive and the carbon particles form aggregates together; and
the aggregates have a median size from 1 to 50 microns;
a G′ storage modulus at −20° C. of the compound, as measured by ASTM D5992-96 (2011), is less than 9 MPa;
a tan delta at −10° C. of the compound, as measured by ASTM D5992-96 (2011), is greater than 0.8;
a tan delta at 0° C. of the compound, as measured by ASTM D5992-96 (2011), is greater than 0.5;
a tan delta at 30° C. of the compound, as measured by ASTM D5992-96 (2011), is less than 0.25;
a G′ storage modulus at 30° C. of the compound, as measured by ASTM D5992-96 (2011), is greater than 1.5 MPa;
a J″ loss compliance at 30° C., as measured by ASTM D5992-96(2011), is greater than 9E-8 1/Pa;
a tan delta at 60° C. of the compound, as measured by ASTM D5992-96 (2011), is less than 0.15; and
a G′ storage modulus at 60° C. of the compound, as measured by ASTM D5992-96(2011), is greater than 1.5 MPa.