Processes for preparing elastomeric composites with mixer ventilation

Abstract

The invention relates to methods for preparing an elastomeric composite comprising filling a mixing chamber with at least one solid elastomer and a filler through a plunger housing and mixing the solid elastomer and the filler in the mixing chamber. The mixing includes moving a plunger through a plunger gap into the mixing chamber to push the elastomer and the filler from the plunger gap downwards into the mixing chamber. The mixing further includes directing a gas stream through the plunger gap from a vent inlet to a vent outlet located in the plunger housing, the gas stream passing through the plunger gap and carrying away at least a portion of a vapor resulting from the mixing, and venting the elastomeric composite from the mixing chamber.

Description

Title of the invention: Processes for preparing elastomeric composites with mixer ventilation. FIELD OF THE INVENTION

[0001] The present invention relates generally to methods for preparing elastomeric composites. More specifically, the present invention relates to methods for providing ventilation in a mixer that prepares or processes an elastomeric composite. BACKGROUND

[0002] Many products can be formed using elastomeric compositions in which a reinforcing filler material is dispersed in any of a variety of synthetic elastomers, natural rubbers, or elastomeric blends. Carbon black and silica, for example, are widely used to reinforce natural rubber and other elastomers. It is common to produce a masterbatch or resulting composite comprising a reinforcing material, an elastomer, and / or various optional additives, such as rubber chemicals, for example, in a batch mixer. These masterbatches are then combined with processing and curing additives and, after curing, generate many products in one or more downstream or subsequent processing steps.These products include, for example, pneumatic and non-pneumatic or solid vehicle tires, including the tread portion comprising the cap and base, the sub-tread, the inner lining, the sidewall, the metal reinforcement, the casing, and other components. Other products include, for example, engine mounts, bushings, conveyor belts, windshield wipers, rubber components for aerospace and marine equipment, vehicle track components, gaskets, coatings, seals, wheels, bumpers, anti-vibration systems, and the like. SUMMARY

[0003] One aspect relates to a process for preparing an elastomeric composite, comprising: (a) fill a mixing chamber of a batch elastomer mixer with at least one elastomer and a charge through a plunger-piston enclosure; (b) mixing the elastomer and the filler in the mixing chamber, which includes: (i) rotate one or more rotors arranged in the mixing chamber, (ii) moving a plunger through a plunger gap into the mixing chamber to push the elastomer and the charge in the plunger gap downwards into the mixing chamber, the plunger gap being defined by the plunger gap, and (iii) directing a gas flow through the plunger-piston space from a vent inlet to a vent outlet disposed in the plunger-piston housing, the gas flow passing through the plunger-piston space and carrying away at least a portion of the vapor resulting from the mixing; and (c) remove the elastomeric composite from the mixing chamber.

[0004] In certain embodiments, the minimum flow rate of the gas flow through the piston-plunger space is at least 200 Nm3 / h, at least 400 Nm3 / h, at least 500 Nm3 / h, at least 750 Nm3 / h, at least 1000 Nm3 / h, at least 1200 Nm3 / h, at least 1500 Nm3 / h, at least 2000 Nm3 / h, at least 2500 Nm3 / h, at least 3000 Nm3 / h, or at least 4000 Nm3 / h and up to 6000 Nm3 / h. In some embodiments, the minimum gas flow rate through the piston-plunger space is between 200 Nm³ / h and 6000 Nm³ / h or between 400 Nm³ / h and 6000 Nm³ / h. In some embodiments, the flow rate is an average flow rate. In some embodiments, the gas flow is continuous. In some embodiments, the gas flow is pulsed.

[0005] Some embodiments further include a ventilation device in gaseous communication with the mixer, the ventilation device being configured to direct the gas so that it flows from the vent inlet to the vent outlet from the plunger space via the vent outlet. In some embodiments, the ventilation device is selected from a fan, a blower, a gas pump, a compressor, an ejector, and a venturi-type diffuser. In some embodiments, the ventilation device is disposed at one or more of the vent inlet and the vent outlet. In some embodiments, the ventilation device is disposed at the vent outlet and is configured to draw gas from the plunger space into the vent outlet.

[0006] In certain embodiments, during mixing, the process further includes a controller configured to: detect, via a pressure sensor, a pressure in the piston-plunger space, and control the ventilation device so that the pressure in the piston-plunger space is at negative pressure.

[0007] In some embodiments, the controller is configured to adjust the gas flow directed by the ventilation device so as to maintain the piston-plunger space at negative pressure. In some embodiments, the controller is configured to adjust the gas flow directed by the ventilation device according to the mixer power.

[0008] In some embodiments, the vent inlets or outlets may be circular, oval, rectangular or square in shape.

[0009] Some embodiments further include the selective opening of one or more of the vent inlet and vent outlet.

[0010] Some embodiments further include opening one or more of the vent inlet and vent outlet during a mixing operation and closing one or more of the vent inlet and vent outlet during filling.

[0011] Some embodiments further include blocking the vent outlet with a gate valve for the vent outlet while the plunger piston is arranged vertically at or above the vent outlet.

[0012] In some embodiments, the vent inlet and vent outlet are arranged on opposite side walls of the plunger housing. In some embodiments, the vent inlet and vent outlet are arranged side by side on a wall forming the plunger housing.

[0013] In some embodiments, the vent inlet and vent outlet are located in an upper part of the plunger housing. In some embodiments, the vent inlet and vent outlet are located in a lower part of the plunger housing. In some embodiments, the vent inlet is located in an upper part of the plunger housing and the vent outlet is located in a lower part of the plunger housing. In some embodiments, the vent inlet is located in a lower part of the plunger housing and the vent outlet is located in an upper part of the plunger housing. In some embodiments, the vent inlet is located in a lower part of the plunger housing and the vent outlet is located in an upper part of the plunger housing. In some embodiments, the vent inlet is located in a lower part of the plunger housing and the vent outlet is located in an upper part of the plunger housing.

[0014] In some embodiments, the vent inlet has a total surface area greater than that of a vent outlet opening. In some embodiments, the vent outlet has a total surface area greater than that of a vent inlet opening.

[0015] In some embodiments, the filling process includes filling the solid elastomer and the filler through a feed hopper gate disposed in the plunger housing. In some embodiments, the vent inlet is disposed above the feed hopper gate. In In some embodiments, the plunger housing includes a rear wall opposite the feed hopper door, with the vent outlet located in the rear wall of the plunger housing. In some embodiments, the vent inlet is located in the rear wall of the housing.

[0016] Some embodiments further include the removal of airborne particles from the plunger housing by means of a hood disposed above one or more of the vent inlet and vent outlet. Some embodiments further include the removal of airborne particles from the plunger housing by means of a hood disposed above the feed hopper door. In some embodiments, a filter or scrubber is disposed between the vent outlet and the ventilation device.

[0017] In some embodiments, the discontinuous elastomer mixer further comprises a vent outlet passage extending from the vent outlet. In some embodiments, the vent outlet passage extends at an upward angle from the vent outlet.

[0018] In some embodiments, the discontinuous elastomer mixer further includes a vent inlet passage extending from the vent inlet.

[0019] In some embodiments, the mixing chamber further includes a vent plunger disposed on the mixing chamber to provide additional ventilation.

[0020] In some embodiments, the charge is a wet charge comprising a liquid, at least part of which evaporates during mixing to generate vapor.

[0021] In some embodiments, the filling in step (a) further includes filling the mixer with at least one binding agent.

[0022] In some embodiments, filling the feed in step (a) includes filling the mixer with the feed contained in low melting point bags. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Reference is made to the accompanying drawings which form an integral part of the present invention, and which illustrate embodiments in which the systems and methods described in this specification can be implemented.

[0024] Fig. 1 illustrates a schematic cross-sectional view of an elastomer mixer according to one embodiment.

[0025] Figure [Fig. 2] illustrates a schematic cross-sectional view of an elastomer mixer according to another embodiment.

[0026] Fig. 3 illustrates a ventilation configuration according to one embodiment.

[0027] Figure 4 illustrates a ventilation configuration according to another mode of realization.

[0028] Fig. 5 illustrates a ventilation configuration according to yet another embodiment.

[0029] Identical reference numbers represent identical elements throughout the document. DETAILED DESCRIPTION

[0030] This document describes methods for providing ventilation to a mixer that processes or prepares elastomeric composites.

[0031] Good dispersion of a reinforcing filler in rubber compounds has been recognized as a factor in achieving consistent mechanical strength and performance of elastomeric composites and rubber compounds. In commercial devices, the filler is dispersed in the rubber under dry mixing conditions using a batch (internal) mixer. For example, more intensive mixing may improve the dispersion of the reinforcing filler but may degrade the elastomer in which the filler is dispersed. This is particularly problematic in the case of natural rubber, which is very susceptible to mechanical / thermal degradation, especially under dry mixing conditions.

[0032] Under typical dry mixing conditions in a batch mixer, there will be little or no emission of steam, moisture, or water vapor. However, certain rubber mixing conditions can result in the release of significant amounts of steam or water vapor: mixing the filler with a latex or emulsion that has not been completely dehydrated (for example, as described in PCT Publication No. WO 2022 / 125683, the description of which is incorporated herein by reference); mixing silica / rubber in the presence of tackifiers to improve reinforcing properties, generating ethanol; and mixing a wet filler with a solid elastomer, as described in PCT Publication No. WO 2020 / 247663, the description of which is incorporated herein by reference, which allows control of batch processing time and temperature beyond what is possible with known dry mixing processes.

[0033] The generation of vapors, such as water vapor, can affect the mixing process in one or more ways: the vapors can condense along the walls of the plunger space, which can lead to fouling of the plunger space by entrained particles and / or condensate dripping into the mixing chamber and interfering with the mixing; the potential for safety hazards can be increased, including the buildup of excessive pressure; and / or there may be a risk of water vapor / steam being released into areas where operators are located. Such undesirable effects can occur, for example, when mixing a wet feed (or a liquid and a feed). (separately filled) with a solid elastomer, or when mixing a (wet or dry) feedstock with a coagulum (for example, as described in PCT Publication No. WO 2022 / 125683 A1, the description of which is incorporated herein by reference), or when mixing silica with an elastomer in the presence of a tackifier in which ethanol is released. When mixing results in vapor formation, significant variations in vapor flow can occur during a batch processing cycle. In some cases, the peak vapor flow can be twice the average vapor flow during portions of the batch processing cycle, or conversely, the vapor flow can be almost zero when the plunger is raised, as occurs when additional ingredients are added to the mixer.

[0034] It has been discovered that current designs of conventional elastomer mixers do not allow for adequate ventilation, for example, when the feed hopper door is closed after at least the elastomer and feed have been added. Although the feed hopper door can remain open during mixing, which may provide some ventilation, operation with the feed hopper door open is not considered safe. Operating a mixer with the feed hopper door open can expose operators to large quantities of vapors and particles and can also expose them to the risk of a sudden release of accumulated pressure. In addition, excessive vapor generation can always occur. Unless otherwise specified, the mixing processes described herein are carried out with the feed hopper door closed.

[0035] This document describes methods for preparing an elastomeric composite comprising at least one elastomer and a filler, wherein the mixing of at least the elastomer and the filler is carried out with sufficient ventilation of the plunger space. In the present method, a gas flow is directed through the plunger space from a vent inlet to a vent outlet, both located within the plunger housing. For mixing processes in which the mixture produces steam, the gas flow passing through the plunger space can carry away at least some of the steam and remove the steam from the mixer. This steam can be generated from the mixture, for example, chemically generated, or by evaporation of a liquid that has been added or was present in one of the filled materials.

[0036] Thus, the processes and apparatus described here make it possible to ensure the ventilation of a mixer which treats or prepares an elastomer composite.

[0037] One aspect relates to a process for preparing an elastomeric composite, comprising: (a) fill a mixing chamber of a batch elastomer mixer with at least one elastomer and a charge through a plunger-piston enclosure; (b) mixing the elastomer and the filler in the mixing chamber to form a mixture, which includes: (i) rotate one or more rotors arranged in the mixing chamber, (ii) move a plunger through a plunger gap into the mixing chamber to push the elastomer and the charge in the plunger gap downwards into the mixing chamber, the plunger gap being defined by the plunger gap, and (iii) directing a gas flow through the plunger-piston space from a vent inlet to a vent outlet disposed in the plunger-piston housing, the gas flow passing through the plunger-piston space and carrying away at least a portion of the vapor resulting from the mixing; and (c) remove the elastomeric composite from the mixing chamber.

[0038] One aspect relates to a method for mixing a filler and an elastomer with simultaneous venting of the plunger-piston space, wherein the plunger-piston space is defined by a plunger-piston enclosure. The method comprises directing a gas flow through the plunger-piston space from a vent inlet to a vent outlet, wherein the vent inlet and vent outlet are positioned on a plunger-piston enclosure.

[0039] Figures 1 and 2 illustrate an elastomer mixer 100, 200 for processing an elastomer material, according to one embodiment. The elastomer mixer 100, 200 can be any suitable mixer capable of combining (e.g., mixing or combining by compounding) a feedstock with an elastomer (e.g., a solid elastomer) to produce rubber compounds. The elastomer mixer 100, 200 can be a batch mixer. A combination of mixers and processes can be used in any of the processes or apparatus described herein, and the mixers can be used sequentially, in tandem, and / or integrated with other processing equipment. The elastomer mixer 100, 200 can be an internal mixer.

[0040] The elastomer mixer 100, 200 may be capable of batch processing, such as an internal mixer. Banbury-type internal mixers are a specific type of internal mixer that can be used for the composite forming processes described herein. The internal mixer may be a tangential internal mixer. The internal mixer may be a geared internal mixer. Other mixers include a kneader-type internal mixer. Commercially available internal mixers from Farrel-Pomini, Harburg Freudenberger Maschinenbau GmbH (HF), Kobe Steel Ltd. or Pelmar Eng'r Ltd can be used.

[0041] The mixer can have any chamber capacity. An internal mixer generally comprises a closed mixing chamber. For batch mixers, the chamber capacity can be at least 1 L, at least 2 L, at least 5 L, at least 10 L, at least 20 L, at least 50 L, at least 100 L, at least 250 L, at least 300 L, at least 600 L or at least 1000 L, for example from 1 L to 1500 L, from 10 L to 1200 L, from 10 L to 1000 L, from 10 L to 750 L, from 10 L to 500 L, from 10 L to 300 L, from 10 L to 100 L, from 20 L to 1500 L, from 20 L to 1200 L, from 20 L to 1000 L, 20 L to 750 L, from 20 L to 500 L, from 20 L to 300 L, from 20 L to 100 L, from 50 L to 1500 L, from 50 L to 1200 L, from 50 L to 1000 L, from 50 L to 750 L, from 50 L to 500 L, from 50 L to 300 L, or from 50 L to 100 L.

[0042] In the illustrated embodiment, the elastomer mixer 100, 200 is a batch mixer comprising one or more of a mixing chamber 110, 210, a plunger housing 120, 220 which defines the plunger space 126, 226 and includes a plunger 124, 224. The elastomer mixer 100, 200 is configured to receive the feed and the elastomer which are filled into the mixer 100, 200, etc., for example, fed through a hopper gate 130, 230. The plunger housing 120, 220 may be provided close to and vertically or above, for example above, the mixing chamber 110, 210. The feed hopper gate 130, 230 can be configured to be open and closed in order to fill or add at least the elastomer, filler, etc. into the elastomer mixer 100, 200.The feed can be filled into the mixer in the form of powder, particles or, in some embodiments, the process includes filling the mixer with the feed contained in low-melting-point bags.

[0043] The plunger housing 126, 226 is configured or otherwise provided to receive the plunger 124, 224 along its vertical stroke and / or to receive the charge, elastomer, etc., to be filled into the mixing chamber 110, 210, for example, configured as a chute. In some embodiments, the plunger housing 120, 220 may have a rectangular cross-section. Although the plunger housing 120, 220 has been described as having a rectangular cross-section, this description is not intended to be limiting. Rather, it is understood that the plunger housing 120, 220 may have other geometric cross-sections, such as triangular, circular, or similar, and / or be configured to match a shape of the plunger 124, 224.

[0044] The plunger piston 124, 224 is lowered to push the charge and the elastomer towards the mixing chamber 110, 210 where mixing begins as soon as the rotors 114, 214 are actuated in chamber 110, 210. The plunger 124, 224, which can also be called the "floating weight" or "plunger", is configured to move vertically towards and away from the mixing chamber 110, 210 in the plunger space 126, 226, for example to apply pressure to the mixture and / or confine the mixture in the mixing chamber 110, 210. The plunger 124, 224 can have different shapes and configurations to apply pressure to the mixture depending on the shape and / or configuration of the mixing chamber 110, 210 and / or the plunger space 126, 226.In some embodiments, the plunger 124, 224 may be V-shaped (in which the "V" points in the direction of the mixing chamber 110, 210), so that the plunger 124, 224 may be configured or otherwise provided as an upper side of the mixing chamber 110, 210, when the plunger 124, 224 is in the extended position, for example, a position where the plunger is oriented downwards.

[0045] The mixing chamber 110, 210 comprises one or more rotors 114, 214 driven by a motor (not shown). The rotors 114, 214 may be meshing rotors, tangential rotors, one or more mixing rotors, etc., capable of mixing and dispersing the filler in the elastomer. A hinged door assembly 119, 219 may be provided at the outlet of the mixing chamber 110, 210 to discharge or discharge the masterbatch and / or the composite from the elastomer mixer 100, 200.

[0046] As shown in Figures 1 and 2, the vent inlet 140, 240 and the vent outlet 150, 250 are arranged in the plunger housing 120, 250 to provide ventilation by allowing the release or evacuation of excess vapor, for example, water vapor, and / or pressure in the plunger housing 120, 220. The vent inlet 140, 240 is configured to supply a gas (for example, air) to the plunger housing 120, 220, while the vent outlet 150, 250 is configured to evacuate the gas and any vapor, liquid, and / or particles carried out of the plunger housing 120, 220 by flowing through the piston-plunger space 126, 226. In some embodiments, the gas is a dry gas and / or has a low relative humidity, for example less than or equal to about 40%, and / or is supplied at a temperature between about 20 and 30 °C.In other embodiments, the gas can be heated to temperatures above 25 °C, for example, from 30 °C to 100 °C. In other embodiments, the gas can be nitrogen, carbon dioxide, a halogen gas, or another inert gas that can be used to sweep or carry away the vapor formed during mixing, for example, a carrier gas to transport and / or convey the vapor resulting from the mixing. In some embodiments, the gas is air, which can be dry air or ambient air (for example, containing the humidity of the environment in which the mixer is located).

[0047] The vent inlet 140, 240 and / or vent outlet 150, 250 may be open connections or may include pipes or conduits of appropriate dimensions to allow sufficient flow. The sizing of the vent inlet 140, 240 and vent outlet 150, 250 can be determined by a person skilled in the art based on the size of the mixer and / or the volumetric flow rate through the vent inlet or vent outlet of the elastomer mixer 100, 200. For example, in some embodiments, the vent outlet 150, 250 may be sized to have a surface area between approximately 10% and 50% of the cross-sectional area of ​​the plunger-piston space 126, 226 in order to avoid high local velocities, which could carry particulate ingredients.In some embodiments, the gas flow rate is lower at vent inlet 140, 240 than at vent outlet 150, 250 in order to avoid pressure loss and to accelerate the removal of airborne particles from the piston-plunger space 126, 226. In some embodiments, vent inlet 140, 240 has a larger opening area than vent outlet 150, 250. The vent inlet and / or vent outlet may be of any shape, for example circular, square, rectangular, oval, and any other shape known for inlets and / or outlets and / or piping, and the like.

[0048] The vent inlet 140, 240 and the vent outlet 150, 250 may each include piping and a gate valve or a valve (not shown) for selectively opening and closing or blocking the vent inlet 140, 240 and / or the vent outlet 150, 250. The gate valve or the valve may be a guillotine gate valve, a butterfly valve, a needle valve, a solenoid valve or similar, configured to selectively open and close the respective vent 140, 240 and 150, 250 (and / or partially open to one or more opening positions, for example with variable opening widths). In some embodiments, tap valves or valves may be provided at positions in the piping where condensate or other deposits do not accumulate, for example to avoid blockage and / or leakage at the joint.

[0049] As illustrated in [Fig. 1], in some embodiments, the vent inlet 140 and the vent outlet 150 are provided at the level of the plunger-piston space 126, in which the vent outlet 150 is provided in a position that is vertically below, for example, in a lower position, relative to the vent inlet 140. Without being limited to theory, it is understood that by placing the vent outlet 150 below the vent inlet 140, the gas drawn in through the vent inlet 140 can be used to carry the vapor resulting from the mixing of the elastomer and the charge, or at least a portion thereof, into the mixing chamber 110 by circulating the gas through the plunger-piston space 126. However, alternative configurations are also conceivable, provided that the arrangement of the vent inlet 140 and the vent outlet 150 allows adequate ventilation of the elastomer mixer 100.

[0050] As illustrated in [Fig. 2], a vent inlet 240 and a vent outlet 250 are arranged on opposite sides of the plunger housing 220 to provide ventilation to the elastomer mixer 200 by allowing the release or venting of excess vapor, for example, water vapor, and / or pressure in the plunger housing 220. The vent inlet 240, positioned above the feed hopper door 230, is configured to supply a gas (for example, air) to the plunger housing 220. In some embodiments, the elastomer mixer 200 may include a cover 241 provided vertically above the vent inlet 240.The cover 241 may be provided around the vent inlet 240, for example, to prevent foreign matter from entering the elastomer mixer 200 and / or to prevent accidental ejection, for example, of vapor, from the elastomer mixer 200, for example, into the operating space around the elastomer mixer 200. In many earlier mixer configurations where a vent inlet is not provided above a feed hopper door 230 (or in any other part of the plunger housing), venting can occur when the feed hopper door is open. However, venting cannot occur once the feed hopper door is closed. Mixing with the feed hopper door open is not considered safe and, therefore, mixing is usually carried out with the feed hopper door closed.Positioning a vent inlet 240 above the feed hopper door provides the necessary inlet gas flow above the feed hopper door 230, when the feed hopper door 230 is closed, for example for mixing. The vent outlet 250 is arranged on a side opposite the vent inlet 240 to allow optimal gas flow through the plunger space 226. The vent outlet 250 is configured to vent the gas and any vapor, liquid and / or particles carried out of the plunger housing 220 that flow through the plunger space 226. As in the embodiment of [Fig. 1], the plunger housing 220 may further include a high-pressure gas (air) line 245. In some embodiments, the high-pressure gas line 245 may replace the vent inlet 240.

[0051] With reference to Figures 1 and 2, in certain embodiments, the elastomer mixer 100, 200 may further comprise a ventilation device 180, 280 which is in gaseous communication with the elastomer mixer 100, 200 and configured to direct the gas so that it flows from vent inlet 140, 240 to vent outlet 150, 250 through the plunger-piston space 126, 226. The fan 180, 280 may be a ventilation device (e.g., an exhaust fan, a variable-speed fan, a centrifugal fan with an open impeller), a blower, a gas pump, a compressor, an ejector, a venturi-type diffuser, or similar. It is understood that the ventilation device 180, 280 may be connected or fluidically coupled to one or more of the vent inlet 140, 240 or the vent outlet 150, 250 (as illustrated in Figures 1 and 2).In some embodiments, the ventilation device 180, 280 can be connected or fluidically coupled via the vent outlet passage which carries the mixture of vapor, for example water vapor, and gas, for example air, to suitable equipment, such as a filter or scrubber 160, 260, in order to remove entrained particles, for example solids and / or liquids (for example droplets). In some embodiments, the venting device 180, 280 can be configured to create a positive pressure in order to push the gas through the piston-plunger space 126, 226 via the vent inlet passage and the vent inlet 140, 240. In some embodiments, the venting device 180, 280 can be configured to create a negative pressure in order to draw the gas through the piston-plunger space 126, 226.The fan 180, 280 may be provided at an outlet and / or above the vent outlet 150, 250, for example with a filter or scrubber 160, 260 disposed between the vent outlet 150, 250 and the venting device 180, 280, as illustrated in Figures 1 and 2, so that the venting device 180, 280 is configured to create a negative pressure in order to draw the gas through the piston-plunger space 126, 226 to entrain the vapor which results and / or is generated by the mixture.

[0052] In some embodiments, the ventilation device 180, 280 is a variable-speed fan, so that the fan speed can be regulated to control the amount of gas drawn through the piston-plunger space 126, 226, for example to control the amount of vapor removed from the piston-plunger space 126, 226. In some embodiments, the ventilation device 180 can be configured or otherwise provided to operate in pulsed mode, for example every 5 seconds, 30 seconds, 1 minute, 2 minutes, 5 minutes or similar, or in intermittent or continuous mode.

[0053] In certain embodiments, the minimum gas flow rate through the piston-plunger space is at least 200 Nm³ / h, at least 400 Nm³ / h, at least 500 Nm³ / h, at least 750 Nm³ / h, at least 1000 Nm³ / h, at least 1200 Nm³ / h, at least 1500 Nm³ / h, at least 2000 Nm³ / h, at least 2500 Nm³ / h, at least 3 000 Nm3 / h, or at least 4000 Nm3 / h and up to 6000 Nm3 / h. In some embodiments, the minimum flow rate of the gas through the piston-plunger space is between 200 Nm3 / h and 6000 Nm3 / h or between 400 Nm3 / h and 6000 Nm3 / h.

[0054] In certain embodiments, the ventilation device 180, 280 is configured to regulate a minimum volumetric flow rate of the gas through the piston-plunger space 126 of at least 200 Nm3 / h, at least 400 Nm3 / h, at least 500 Nm3 / h, at least 750 Nm3 / h, at least 1000 Nm3 / h, at least 1200 Nm3 / h, at least 1500 Nm3 / h, at least 2000 Nm3 / h, at least 2500 Nm3 / h, at least 3000 Nm3 / h, or at least 4000 Nm3 / h and up to 6000 Nm3 / h. It should be noted that the gas flow rate can be based on the size of the mixer 100; for example, the larger the mixer, the higher the gas flow rate. In some embodiments, the ventilation device 180, 280 is configured to have a minimum gas flow rate through the piston-plunger space between 200 Nm³ / h and 6000 Nm³ / h, or between 400 and 6000 Nm³ / h, for example between 200 Nm³ / h and 5000 Nm³ / h, between 200 Nm³ / h and 4000 Nm³ / h, between 400 Nm³ / h and 5000 Nm³ / h, or between 400 Nm³ / h and 4000 m³ / h.In some embodiments, the flow rate may be under normal / standard conditions, for example STP (operating temperature = 20 °C at 1 atm; "N" refers to the normal condition of 0 °C, 1 atm). In some embodiments, the gas flow rate through the piston-plunger gap 126, 226 is the average flow rate. In some embodiments, the flow rate may be adjusted according to the type of elastomer and / or filler.

[0055] A hood (not shown) can be configured to remove vapor, airborne particles, and similar elements during the mixing process. The hood can be disposed over the vent inlet, the vent outlet, or both. In some embodiments, the hood may include and / or be connected to a separate ventilation device that provides negative pressure across the plunger-piston space 126, 226, and / or be connected to a ventilation device 180, 280.

[0056] The controller 170, 270 is configured, designed, or otherwise programmed to provide operational control of the elastomer mixer 100, 200, for example, a processor-enabled controller programmable to provide operational control. In some embodiments, the controller 170 is electrically connected (or wirelessly connected) (hereinafter "connected") to one or more components of the elastomer mixer 100, 200, such as one or more sensors 190, 290, the venting device 180, 280, the mixer 110, 210, the plunger 124, 224, the feed hopper door 130, 230, etc. The sensor 190, 290 may be one or more of a pressure sensor, a humidity sensor, and / or a temperature sensor. The sensor 190, 290 can be positioned at one or more locations, such as in an inner wall of the plunger housing 120, 220, in the plunger space 126, 226, for example, in the immediate vicinity of the vent outlet 150, 250, or in an inner wall of a pipe leading to the vent outlet 150, 250. In some embodiments, the controller 170 is configured to detect, via the sensor 190, 290 provided in the plunger space 126, 226, a pressure in the plunger space 126, 226, and to control the venting device 180, 280 so as to maintain the pressure in the plunger space 126 at negative pressure, for example, by increasing the gas suction flow rate if a negative pressure is present. A higher level is needed.

[0057] In certain embodiments, during a filling or loading operation, the controller 170, 270 can be configured to fully or partially close one or more of the vent inlet 140, 240 or the vent outlet 150, 250, for example by closing one or more gate valves or gates (not shown) in the inlet 140, 240 and / or the outlet 150, 250.

[0058] In certain embodiments, the piston-plunger housing may have more than one vent inlet in combination with one or more vent outlets to obtain the desired flow rate. In certain embodiments having more than one vent inlet or vent outlet, the vent inlet(s) have a total opening area greater than the total opening area of ​​the vent outlet(s). In some embodiments, an additional vent inlet may take the form of a high-pressure line 145, 245 (as illustrated in Figures 1 and 2), to supply high-pressure gas to the piston-plunger space 126, 226. In some embodiments, the high-pressure line 145, 245 is provided in addition to the vent inlet 140, 240. In other embodiments, the high-pressure line 145, 245 may be the vent inlet; for example, it may replace the vent inlet 140, 240.

[0059] In certain embodiments, a vent outlet may be positioned in the mixing chamber 110, 220 (not shown), in addition to the vent outlet 150, 250. The vent outlet on the mixing chamber may be, for example, a vent plunger designed to achieve a desired flow rate and / or to allow periodic, pulsed, or continuous ventilation. Examples of a vent plunger are described in U.S. Provisional Application No. 63 / 707,506, filed October 15, 2024, the description of which is incorporated herein by reference.

[0060] In certain embodiments, one or more of the piston-plunger housing 126, 226 or the vent outlet 150, 250 may be isolated in order to reduce the condensation along the walls of the piston-plunger space and / or the mixing chamber.

[0061] Although Figures 1 and 2 illustrate the elastomer mixer 100, 200 intended for the processing or preparation of an elastomer material, it is understood that this description is not intended to be limiting. Rather, it is understood that the elastomer mixer 100, 200 may be part of a larger mixing apparatus, which may include one or more elements from among one or more mixers, extruders, cutting devices, dryers, balers, rollers or cylinders, or the like. It is further understood that the elastomer mixer 100, 200 may also be supplied as a separate component / operation for the mixing apparatus or as an integral part of the mixing apparatus, for example, as a single / integrated unit.

[0062] Although various positionings of the vent inlet(s) 140, 240 and the vent outlet(s) 150, 250 are described above, it is understood that this description is not intended to be limiting. Rather, it is understood that the vent inlet(s) 140, 240 and / or the vent outlet(s) 150, 250 may have different configurations and / or positions along the plunger housing 120, 220 so that gas, such as air, may be drawn through the plunger space 126, 226 to ensure sufficient ventilation for the elastomer mixer 100, 200, for example, when the elastomer mixer is used for mixing processes that result in the generation of steam. For example, in some embodiments, the vent inlet and vent outlet can be arranged side by side in the piston-plunger housing 120, 220, for example on the same side or on the same wall of the piston-plunger housing 120, 220.In other embodiments, the vent outlet may be provided above the plunger housing 120, 220 in a vertical direction to ensure sufficient ventilation of the plunger space 126, 226, for example, to allow gas to be drawn through the plunger space to carry away at least some of the steam. In some embodiments, the vent outlet and / or vent inlet may be provided vertically and located in an upper part of the plunger housing 120, 220, to ensure better gas circulation for steam removal, for example, above the plunger housing 120, 220, in the upper part of the plunger housing 120, 220, and / or through the pneumatic actuator housing.In some embodiments, the vent inlet and vent outlet are located on opposite sides of the piston-plunger space 126, 226, and the piston-plunger space 126, 226 is located between the vent inlet and vent outlet. In some embodiments, the vent outlet and / or vent inlet are located in a . lower part of the plunger housing 120, 220, for example closer to the mixing chamber 110, 210. In some embodiments, the vent inlet is located above the feed hopper door 130, 230 and / or the plunger housing 120, 220 includes a rear wall opposite the feed hopper door 130, 230, and the vent outlet is located in the rear wall of the plunger housing 120, 220. In some embodiments, the vent inlet is located in the rear wall of the plunger housing 120, 220. In some embodiments, the vent inlet and vent outlet are located in opposite side walls of the plunger housing 120, 220, for example walls adjacent to the feed hopper door 130, 230.In some embodiments, the vent inlet is located in an upper part of the piston-plunger housing and the vent outlet is located in a lower part of the piston-plunger housing; or the vent inlet is located in a lower part of the piston-plunger housing and the vent outlet is located in an upper part of the piston-plunger housing. Thus, depending on the positioning of the vent inlet and vent outlet, a ventilation device 180, 280 can be configured to draw in or push gas, such as air, through the plunger-piston space 126, 226 to ensure sufficient ventilation for the elastomer mixer 100, 200, and / or be configured to provide a safety function by allowing the release or discharge of excess vapor, for example water vapor, and / or pressure in the plunger-piston enclosure 120, 220 and / or the plunger-piston space 126, 226.

[0063] For example, figures 3 to 5 illustrate various embodiments of the vent inlet 140, 240 and the vent outlet 150, 250 usable with the elastomer mixer 100, 200, as described above.

[0064] As illustrated in Figures 3 to 4, in certain embodiments, one or more vent inlets 340 and one or more vent outlets 350 may be provided on a back plate 392 of the elastomer mixer, for example 100, 200, in the plunger space 126, 226. The back plate 392 may be provided on a wall of the plunger housing 120, 220, defining the plunger space 126, 226, opposite the feed hopper door 130, 230. The vent inlet(s) 340, in this embodiment, are provided vertically above the vent outlet 350. The vent inlet(s) 340 and vent outlet(s) 350 may include piping provided at an angle ascending relative to vent inlet 340 and / or vent outlet 350, for example between about 50 degrees and 90 degrees relative to the wall of the plunger-piston enclosure 120, 220.

[0065] As illustrated in [Fig. 4], in certain embodiments, the vent inlet(s) 340 and / or the vent outlet(s) 350 may include fittings Vent fittings 394 are configured to connect the vent inlet(s) 340 and the vent outlet(s) 350 to one or more of a vent outlet passage and / or a vent inlet passage, respectively. In some embodiments, the vent outlet passage and / or the vent inlet passage extend from the respective vent outlet 350 or vent inlet 340 at an upward angle relative to the vent outlet 350 or the vent inlet 340. The vent fittings 394 may be provided to couple vent ducts and / or piping having different geometries or materials to the vent inlet 340 and / or the vent outlet 350, for example, a round-to-straight adapter and / or a rubber-to-steel adapter, or similar.

[0066] Figure 5 illustrates another embodiment of a vent inlet 540 and vent outlet 550 assembly. In this embodiment, one or more of the vent inlet 540 and / or vent outlet 550 may be provided on a wall of the plunger housing 120, 220 of the elastomer mixer 100, 200. The vent inlet 540 and vent outlet 550 may be provided on an opposite wall of the plunger housing 120, 220, defining the plunger space 126, 226, relative to the feed hopper door 130, 230. The vent inlet 540 and / or vent outlet 550 include piping that has an angled portion. 544 which is bent opposite the piston-plunger housing 120, 220, for example in a downward direction, for example towards the bottom of the elastomer mixer 100, 200, and then inclined in an upward direction.Thus, the elbow 544 can be configured or otherwise provided to collect any condensate formed from the vapor generated by the mixing of the elastomer and the filler. In some embodiments, the elbow 544 may include a valve 545, for example, a manual valve or an automatic valve, such as a solenoid, to drain the condensate from the elbow 544. The vent inlet 540 and / or vent outlet 550 may further include vent fittings 594 that are configured to connect the vent inlet 540 and the vent outlets 550 to one or more of a vent outlet passage and / or a vent inlet passage, respectively. Vent fittings 594 can be provided for coupling vent ducts and / or piping having different geometries or materials to vent inlet 540 and / or vent outlet 550, for example a round to straight adapter and / or a rubber to steel adapter, or similar..

[0067] The processes for processing or preparing the elastomeric composite, as described herein, are as follows. The process for preparing an elastomeric composite includes filling a mixing chamber, for example 110, 210, of a batch elastomer mixer, for example 100, 200, with at least one elastomer, a filler, etc., through a plunger chamber, for example 120, 220. The process further includes mixing the elastomer and the filler in the mixing chamber, for example 110, 210, to form a mixture.The mixing process includes the rotation of one or more rotors, for example 114, 214, arranged in the mixing chamber, for example 110, 210, and the movement of a plunger, for example 124, 224, through a plunger gap, for example 126, 226, into the mixing chamber, for example 110, 210, in order to push the elastomer and the charge in the plunger gap, for example 120, 220, downwards into the mixing chamber, for example 110, 210, by directing a gas flow through the plunger gap, for example 126, 226, from a vent inlet, for example 140, 240, to a vent outlet, for example 150, 250, arranged in the chamber. piston-plunger, for example 120, 220, the gas flow passing through the piston-plunger space, for example 126, 226, and carrying away at least some of the vapor resulting from the mixing, and evacuating the elastomer composite from the mixing chamber, for example 110, 210. .

[0068] In some embodiments, during a filling or loading step or operation, the process may include closing one or more of the vent inlet, for example 140, 240, or the vent outlet, for example 150, 250, for example by closing the gate valve(s) or the valve(s).

[0069] During a mixing operation, the process includes closing the feed hopper door, for example 130, 230, moving the plunger, for example 124, 224, to the extended position, which extends the plunger, for example 124, 224, through the plunger space, for example 126, 226, towards the mixing chamber, for example 110, 210, in order to push the charge, the elastomer, etc. towards the mixing chamber, and the opening of one or more of the gate valves or gates, once the plunger, for example 124, 224, is positioned so as to form an upper side of the mixing chamber, for example 110, 210. As discussed above, during the mixing operation, at least some of the steam resulting from the mixing is removed.For example, steam from the mixture can flow into the plunger space, e.g. 126, 226, so that steam (and / or particles and / or liquid) is present in the plunger space, e.g. 126, 226, e.g. through the passage of steam through the clearance between the plunger, e.g. 124, 224, and the mixer 110, 210 (e.g., groove wear plates) and / or between the plunger, e.g. 124, 224, and the plunger space, e.g. 126, 226.

[0070] The method may further include directing the gas flow through the piston-plunger space, for example 126, 226, by controlling the ventilation device, for example 180, 280, to pass (or draw) the gas through the plunger space, for example 126, 226, in order to entrain and / or mix the vapor with the gas and / or particles and / or liquid, for example, by partially joining or displacing the vapor and / or particles and / or liquid from the plunger space, for example 126, 226. In some embodiments, the method includes regulating the gas flow to maintain a negative pressure in the plunger space, for example 126, 226, by controlling the venting device, for example 180, 280, for example by regulating the speed or positions of one or more of the vent inlet, for example 140, or the vent outlet, for example 150, 250. In some embodiments, the controller 170, 270 is configured to adjust a gas flow directed by the ventilation device 180, 280 according to the power of the mixer.In some embodiments, gate valves or gates, for example 142, 152, 252, are opened selectively, for example depending on the operation and the amount of steam to be drawn in or discharged from the piston-plunger space.

[0071] In some embodiments, the method includes regulating the fan, for example 180, 280, which is in gaseous communication with the elastomer mixer 100, 200, so that the gas flows from the vent inlet, for example 140, 240, to the vent outlet, for example 150, 250, from the plunger space, for example 126, 226, via the vent outlet, for example 150, 250. In some embodiments, the ventilation device, for example 180, 280, may be disposed at one or more of the vent inlet, for example 140, 240, or the vent outlet, for example 150, 250. In some embodiments, the method may include regulating the fan, for example 180, 280, so that the pressure in the piston-plunger space, for example 126, 226, is maintained at a negative pressure, for example as part of a suction.

[0072] In some embodiments, the method includes regulating the fan, for example 180, 280, so that the gas flow rate is lower at the vent inlet, for example 140, 240, than at the vent outlet, for example 150, 250, in order to prevent pressure loss and accelerate the removal of airborne particles from the plunger-piston enclosure, for example 120, 220.

[0073] In certain embodiments, the method includes regulating the fan 180, 280 to maintain a minimum flow rate of the gas through the piston-plunger space, for example 126, 226, which is at least 400 m³ / h, preferably at least 500 m³ / h, more preferably at least 750 m³ / h, more preferably at least 1000 m³ / h, more preferably at least 1200 m³ / h, more preferably at least 1500 m³ / h, more preferably at least 2000 m³ / h, more preferably at least 2500 m3 / h, more preferably at least 3000 m3 / h. It is understood that the flow rate may depend on the size of the elastomer mixer, for example 100, 200.

[0074] In certain embodiments, ventilation can be achieved with an open feed hopper door 130, 230 intended to function as an additional air inlet. The gas flow will pass through the inlet 140, 240 and the feed hopper door 130, 230 and exit the piston-plunger space through the vent outlet 150, 250, in order to prevent particles from escaping through the feed hopper door 130, 230. The use of the feed hopper door 130, 230 may require a reduction in the gas flow to prevent the entrainment of feed materials.

[0075] In other embodiments, an additional gas flow can be introduced into the outlet 150, 250 upstream of the filter or scrubber 160, 260, for example a venturi scrubber. This ensures that the gas flow through the scrubber 160, 260 does not fall below the level required to adequately remove particulate matter.

[0076] Once the mixing is complete, the process includes opening the hinged door assembly, for example 119, 219, to discharge or pour the master mix and / or the composite from the elastomer mixer, for example through the mixing chamber, for example 110, 210. In some embodiments, the step of discharging the mixing chamber, for example 110, 210, occurs and results in a composite comprising the filler dispersed in the elastomer at a rate of at least 1 phr, for example at least 10 phr or at least 20 phr. During the mixing cycle, the mixture undergoes a temperature increase. It is desirable to avoid excessive temperature increases that would degrade the elastomer.Evacuation (e.g., "spillover" in a batch mixture) can occur as a function of time or temperature, or specific energy, or power, or the torque applied to the rotors, the rotor speed, or a combination of one or more of these parameters. The parameter(s) can be selected to minimize elastomer degradation and / or to achieve a target property, e.g., moisture content, Mooney viscosity, etc., of the composite. Methods for determining evacuation are described in patents GB2163061B, US4818113A, US6817748B2, EP3266576B1, KGK Rubberpoint, July-August, p. 28 (2009), and KGK Rubberpoint vol. 10, p. 31 (2015) (available at www.kgk-rubberpoint.de), the descriptions of which are incorporated herein by reference. .

[0077] Thus, in certain embodiments, the elastomer composite preparation process ensures sufficient ventilation of the elastomer mixer, for example, to prevent and / or reduce condensation in the plunger chamber 120, 220 and / or to allow the release of excess pressure accumulated in the mixing chamber. In other words, when vapor generation, whether by evaporation or chemical reaction, occurs at a high rate, the present process ensures a gas flow from a vent inlet and through the plunger space, such that the gas flow draws or pushes the gas, which carries and / or mixes with the vapor, out of the plunger space, via the vent outlet, to the outside of the elastomer mixer.Thus, the elastomer mixer ensures sufficient ventilation of the vapor resulting from the mixing, so as to prevent or mitigate the formation of condensate on the walls of the piston-plunger space and / or to avoid causing an accumulation of excess pressure.

[0078] In some embodiments, the elastomeric composition is a composite comprising at least one elastomer and at least one filler having a rate, or content, of at least 20 phr.

[0079] The elastomer may be a solid elastomer, for example having a liquid content of 5% by weight or less, relative to the total weight of the solid elastomer, such as 4% by weight or less, 3% by weight or less, 2% by weight or less, 1% by weight or less, or from 0.1% by weight to 5% by weight, from 0.5% by weight to 5% by weight, from 1% by weight to 5% by weight, from 0.5% by weight to 4% by weight, etc. In other embodiments, the elastomer may be a never-dried natural rubber containing water in an amount of between 5% and 55% by weight, or between 10% and 55% by weight, or between 20% and 55% by weight of the never-dried natural rubber, such as a coagulum (for example, as described in PCT Publication No. WO 2022 / 125683 A1, the description of which is incorporated herein by reference).

[0080] Exemplary elastomers include natural rubber (NR), functionalized natural rubber (e.g., epoxy natural rubber (ENR)), synthetic elastomers such as styrene-butadiene rubber (SBR, e.g., solution SBR (SSBR), emulsion SBR (ESBR) or oil-extended SSBR (OESSBR)), functionalized styrene-butadiene rubber, polybutadiene rubber (BR), functionalized polybutadiene rubber, polyisoprene rubber (IR), ethylene-propylene rubber (EPDM), isobutylene-based elastomers (e.g., butyl rubber), halogenated butyl rubber (e.g., chlorinated butyl rubber (CIIR), brominated butyl rubber (BIIR)), polychloroprene rubber (CR), nitrile rubbers (NBR), hydrogenated nitrile rubber (HNBR), fluoroelastomers, Perfluoroelastomers and silicone rubbers. Optionally, the elastomer can be chosen from at least one of natural rubber, styrene-butadiene rubber and polybutadiene rubber, including mixtures thereof.

[0081] Other synthetic polymers that can be used in current processes (alone or in mixtures) include hydrogenated SBR and thermoplastic block copolymers (e.g., those that are recyclable). Synthetic polymers include ethylene, propylene, styrene, butadiene, and isoprene copolymers. Other synthetic elastomers include those synthesized using metallocene chemistry, in which the metal is selected from Ce, Pr, Nd, Sm, Gd, Tb, Dy, Ho, Tm, Yb, Lu, Co, Ni, and Ti.Polymers made from bio-derived monomers may also be used, such as modern carbon-containing monomers as defined by ASTM D6866, for example, polymers made from bio-derived styrene monomers described in U.S. Patent No. 9868853, the description of which is incorporated herein by reference, or polymers made from bio-derived monomers such as butadiene, isoprene, ethylene, propylene, farnesene, and their comonomers.

[0082] Other exemplary elastomers include, but are not limited to, rubbers, polymers (e.g. homopolymers, copolymers and / or terpolymers) of 1,3-butadiene, styrene, isoprene, isobutylene, 2,3-dialkyl-1,3-butadiene, where the alkyl group may be a methyl, ethyl, propyl, etc., acrylonitrile, ethylene, propylene and the like.

[0083] Other applicable elastomers that can be used in the processes described herein are described in PCT Publication No. WO 2020 / 247663, the description of which is incorporated herein by reference.

[0084] If two or more elastomers are used, they may be loaded into the mixer as a mixture all at once (in a single batch or in two or more batches), or they may be added separately in any order and in any quantity. For example, the elastomer may comprise natural rubber mixed with one or more of the elastomers described herein, for example, butadiene rubber and / or styrene-butadiene rubber, or SBR mixed with BR, etc. For example, the additional elastomer may be added separately to the mixer, and the natural rubber may be added separately to the mixer.

[0085] The elastomer may be or comprise natural rubber. If the elastomer is a mixture, it may comprise at least 50% by weight, at least 70% by weight, or at least 90% by weight of natural rubber. The mixture may further comprise synthetic elastomers, such as one or more of the following: styrene-butadiene, functionalized styrene-butadiene rubber, and polybutadiene rubber, and / or any other elastomer described herein.

[0086] Natural rubber can also be chemically modified in one way or another. For example, it can be treated to chemically or enzymatically modify or reduce various non-rubber components, or the rubber molecules themselves can be modified with various monomers or other chemical groups such as chlorine. Other examples include epoxy-coated natural rubber and natural rubber having a nitrogen content of not more than 0.3% by weight, as described in PCT Publication No. WO 2017 / 207912.

[0087] At least one filler may be selected from carbonaceous materials, carbon black, silica, nanocellulose, lignin, clays, nanoclays, metal oxides, metal carbonates, pyrolysis carbon, regenerated carbon, recovered carbon black (for example, as defined in ASTM D8178-19, rCB), graphene, graphene oxides, reduced graphene oxide (for example, reduced graphene oxide worms as described in PCT Publication No. WO 2019 / 070514A1, the description of which is incorporated herein by reference), or densified reduced graphene oxide granules (as described in U.S. Provisional Application No. 62 / 857,296, filed June 5, 2019, and PCT Publication No. WO 2020 / 247681, the (Descriptions are incorporated here by reference), of carbon nanotubes, single-walled carbon nanotubes, multi-walled carbon nanotubes, or combinations thereof,or corresponding coated materials (e.g., silicon-treated carbon black) or materials chemically treated with these (e.g., chemically treated carbon black). Other suitable fillers include carbon nanostructures (CNS), a plurality of carbon nanotubes (CNTs) that are cross-linked in a polymer structure by being branched, e.g., dendrimerically, interdigitated, entangled, and / or sharing common walls with one another. CNS fillers are described in U.S. Patent No. 9,447,259 and PCT Application No. PCT / US2021 / 027814, the descriptions of which are incorporated herein by reference. Mixtures may also be used, e.g., mixtures of silica and carbon black, silica and silicon-treated carbon black, and carbon black and silicon-treated carbon black. The filler may be chemically treated (e.g., chemically treated carbon black,chemically treated silica, silicon-treated carbon black) and / or chemically modified. The filler may be, or may include, carbon black having one or more attached organic groups. The filler may have one or more coatings (e.g., silicon-coated materials, silica-coated materials, carbon-coated materials). The filler may be oxidized and / or undergo other surface treatments. It, there are no limitations as to the type of filler (e.g., silica, carbon black or other filler) that can be used.

[0088] The filler can generally be any conventional filler used with elastomers, such as reinforcing fillers, including, but not limited to, carbon black, silica, a filler comprising carbon black, a filler comprising silica, and / or any combination thereof. The filler can be particulate, fibrous, or plate-like. For example, a particulate filler consists of discrete bodies. These fillers often have an aspect ratio (e.g., length / diameter) of 3:1 or less, or 2:1 or less, or 1.5:1 or less. Fibrous fillers can have an aspect ratio, for example, of 2:1 or more, 3:1 or more, 4:1 or more, or even greater. In general, fillers used for reinforcing elastomers have microscopic (e.g., hundreds of microns or less) or nanometric (e.g., less than 1 micron) dimensions.In the case of carbon black, discrete bodies of particulate carbon black refer to the aggregates or agglomerates formed from primary particles, and not to the primary particles themselves. In other embodiments, the filler may have a plate-like structure, such as graphene and reduced graphene oxides.

[0089] The filler may include a fibrous filler comprising natural fibers, semi-synthetic fibers, and / or synthetic fibers (for example, nanometric carbon filaments), such as the short fibers described in PCT Publication No. WO 2021 / 153643, the description of which is incorporated herein by reference. Other fibrous fillers include poly(p-phenylene terephthalamide) paste, commercially available as Kevlar® paste (DuPont).

[0090] Other suitable fillers include materials of biological or bio-based origin (derived from biological sources), recycled materials or other fillers considered renewable or sustainable, including hydrothermal carbon (HTC, where the filler comprises lignin that has been treated by hydrothermal carbonization as described in U.S. Patent Nos. 10035,957 and 10428,218, the descriptions of which are incorporated herein by reference), rice hull silica, carbon from methane pyrolysis, nanocrystalline cellulose starch particles, polysaccharides, glucans, dextran, microfibrillated cellulose, modified polysaccharide particles, starch, silica earth, granulated rubber and functionalized granulated rubber.The exemplary modified polysaccharides include those described in U.S. Patent Publications Nos. 2020 / 0181370 and 2020 / 0190270, the descriptions of which are incorporated herein by reference. For example, the polysaccharides may be selected from: poly alpha-1,3-glucan; poly alpha-1,3-1,6-glucan; an alpha- polymer. (1,3-glucan) insoluble in water having 90% or more of α,3-glycosidic bonds, less than 1% by weight of α-α,3,6-glycosidic branching points and a number-average degree of polymerization between 55 and 10,000; dextran; a composition comprising a poly α-1,3-glucan ester compound; and water-insoluble cellulose having a weight-average degree of polymerization (DPw) of about 10 to about 1,000 and a cellulose type II crystal structure.

[0091] Carbon black may be furnace black, gas black, thermal black, acetylene black or lamp black, plasma black, reclaimed carbon black (for example, as defined in ASTM D8178-19), or a carbon product containing silica and / or metallic and similar species. The carbon black used in any of the processes described herein may be of any grade of strengthening carbon black and semi-strengthening carbon black. Examples of strengthening grades according to ASTM are carbon blacks NI 10, N121, N134, N220, N231, N234, N299, N326, N330, N339, N347, N351, N358, and N375. Examples of semi-reinforcing grades according to ASTM standards are carbon blacks N539, N550, N650, N660, N683, N762, N765, N774, N787, N990 and / or thermal blacks of grade N990.

[0092] Carbon black can have any surface area per statistical thickness (STSA), for example, from 20 m² / g to 250 m² / g or more. The surface area per statistical thickness (STSA) is determined according to the test procedure ASTM D-5816 (measured by nitrogen adsorption). Carbon black can have a compressed oil absorption (COAN) index from about 30 ml / 100 g to about 150 ml / 100 g. The compressed oil absorption (COAN) index is determined according to ASTM D3493. Optionally, carbon black can have an STSA between 20 m2 / g and 180 m2 / g, or between 60 m2 / g and 150 m2 / g with a CO AN index between 40 ml / 100 g and 115 ml / 100 g or between 70 ml / 100 g and 115 ml / 100 g.

[0093] As noted, carbon black can be a rubber black, and in particular a carbon black of reinforcing or semi-reinforcing grade. Carbon blacks sold under the registered trademarks Regai®, Black Pearls®, Spheron®, Sterling®, Propel®, Endure®, and Vulcan® available from Cabot Corporation; the registered trademarks Raven®, Statex®, Fumex®, and Neotex® and the CD and HV ranges available from Birla Carbon (formerly available from Columbian Chemicals); as well as the registered trademarks Corax®, Durax®, Ecorax®, and Purex® and the CK range available from Orion Engineered Carbons (formerly Evonik and Degussa Industries); and other fillers suitable for use in rubber or tire-related applications, can also be used in various applications. Carbon blacks Chemically suitable functionalized carbon blacks include those described in patents WO 96 / 18688 and US2013 / 0165560, the descriptions of which are incorporated herein by reference. Mixtures of any of these carbon blacks may be used. Carbon blacks having surface areas and structures exceeding the ASTM grades and typical values ​​selected for blending with rubber, such as those described in US patent application publication No. 2018 / 0282523, the description of which is incorporated herein by reference, may be used.

[0094] With regard to the filler, optionally, at least silica, one or more types of silica, or any combination of silica(s), may be used in any embodiment described herein. The silica may include or be precipitated silica, fumed silica, silica gel, and / or colloidal silica. The silica may be or include untreated silica and / or chemically treated silica. The silica may be suitable for reinforcing elastomeric composites and may be characterized by a specific surface area according to the Brunaur-Emmett-Teller (BET, determined by multipoint nitrogen adsorption BET, ASTM D1993) method of approximately 20 m² / g to approximately 450 m² / g; approximately 30 m² / g to approximately 450 m² / g; approximately 30 m² / g to approximately 400 m² / g; or from about 60 m2 / g to about 250 m2 / g, from about 60 m2 / g to about 250 m2 / g, from about 80 m2 / g to about 200 m2 / g.Silica can have a dispersibility standard (DSS) ranging from approximately 80 m² / g to 250 m² / g, for example, between approximately 80 m² / g and 200 m² / g, or between 90 m² / g and 200 m² / g, between 80 m² / g and 175 m² / g, or between 80 m² / g and 150 m² / g. Highly dispersible precipitated silica can be used as a filler in current processes. Highly dispersible precipitated silica (HDS) is defined as any silica with a substantial capacity to deagglomerate and disperse within an elastomeric matrix. It is known that such dispersion determinations can be observed by electron or optical microscopy on thin sections of elastomeric composite. Among the commercial grades of HDS, we can mention Perkasil® GT 3000GRAN silica from WR Grâce & Co, Ultrasil® 7000 silica from Evonik Industries, Zeosil® 1165 MP, 1115 MP, Premium and 1200 MP silicas from Solvay SA, Hi-Sil® EZ 160G silica from PPG Industries, Inc. and Zeopol®8741 or 8745 silica from Evonik Industries.Conventional precipitated silica without HDS can also be used. Examples of commercial grades of conventional precipitated silica include Perkasil® KS 408 silica from WR Grâce & Co., Zeosil® 175GR silica from Solvay SA, Ultrasil® VN3 silica from Evonik Industries, and Hi-Sil® 243 silica from PPG Industries, Inc. Precipitated silica with surface-fixed silane binding agents can also be used. Examples of commercial grades of chemically treated precipitated silica include... Agilon® 400, 454 or 458 silica from PPG Industries, Inc. and Coupsil silicas from Evonik Industries, for example Coupsil® 6109 silica.

[0095] Carbon black can be a multiphase aggregate comprising at least one carbon phase and at least one phase containing metallic species or a phase containing silica species, i.e., silicon-treated carbon black. In silicon-treated carbon black, a silicon-containing species, such as silicon oxide or silicon carbide, is distributed throughout at least a portion of the carbon black aggregate as an intrinsic part of the carbon black. Silicon-treated carbon blacks are not carbon black aggregates that have been coated or otherwise modified, but rather represent particles of two-phase aggregates. One phase is carbon, which will always be present in the form of graphitic crystallite and / or amorphous carbon, while the second phase is silica, and possibly other silicon-containing species.Thus, the phase of silicon-containing species in silicon-treated carbon black is an intrinsic part of the aggregate, distributed throughout at least a portion of the aggregate. Silicon-treated Ecoblack™ carbon blacks are available from Cabot Corporation. The manufacture and properties of these silicon-treated carbon blacks are described in U.S. Patent No. 6,028,137, a description of which is incorporated herein by reference.

[0096] Silicon-treated carbon black may include regions containing silicon primarily on the surface of the carbon black aggregate, while remaining part of the carbon black, and / or silicon-treated carbon black may include regions containing silicon distributed throughout the carbon black aggregate. Silicon-treated carbon black may be oxidized. Silicon-treated carbon black can contain from about 0.1% to about 50% silicon by weight, for example, from about 0.1% to about 46.6%, from about 0.1% to about 46%, from about 0.1% to about 45%, from about 0.1% to about 40%, from about 0.1% to about 35%, from about 0.1% to about 30%, from about 0.1% to about 25%, from about 0.1% to about 20%, from about 0.1% to about 15%, from about 0.1% to about 10%, from about 0.1% to about 5%, or from about 0.1% to about 2% by weight, depending on the weight of the silicon-treated carbon black.These quantities can range from approximately 0.5% to approximately 25% by weight, from approximately 1% to approximately 15% by weight of silicon, from approximately 2% to approximately 10% by weight, from approximately 3% to approximately 8% by weight, from approximately 4% to approximately 5% or approximately 6% by weight, all these quantities being a function of the weight of the silicon-treated carbon black.

[0097] In any embodiment and at any stage, a tackifying agent may be introduced in any one of the stages (or in several stages or locations) as long as the tackifying agent has the possibility of dispersing in the composite. The bonding agent may be or include one or more silane bonding agents, one or more zirconate bonding agents, one or more titanate bonding agents, one or more nitro bonding agents, or any combination thereof.The bonding agent may be or include bis(3-triethoxysilylpropyl)tetrasulfane (e.g., Evonik Industries' Si 69, Struktol Company's Struktol SCA98), bis(3-triethoxysilylpropyl)disulfane (e.g., Evonik Industries' Si 75 and Si 266, Struktol Company's Struktol SCA985), 3-thiocyanatopropyl-triethoxysilane (e.g., Evonik Industries' Si 264), gamma-mercaptopropyl-trimethoxysilane (e.g., Evonik Industries' VP Si 163, Struktol Company's Struktol SCA989), gamma-mercaptopropyl-triethoxysilane (e.g., Evonik Industries' VP Si 263), zirconium dineoalkanolatodi(3-mercapto)propionato-O, N,N'-bis(2-methyl-2-nitropropyl)-l,6-diaminohexane, S-(3-(triethoxysilyl)propyl)octanethioate (e.g., Momentive, Friendly, WV's NXT tackifier), and / or tackifiers that are chemically similar or that have one or more identical chemical groups.Other specific examples of tackifiers, indicated here by their trade names, include, but are not limited to, Evonik Industries' VP Si 363 and Momentive's NXT Z and NXT Z-50 silanes. Other compounds that can function as tack-agents include compounds containing a nitroxide radical, for example TEMPO (2,2,6,6-tetramethyl-l-piperidinyloxy radical), as described in U.S. Patent Nos. 6084015, 6 194509, 8584725 and U.S. Publication No. 2009 / 0292044, the descriptions of which are incorporated herein by reference, or 1,3-dipolar nitrile oxide, nitrile imine and nitrone compounds, as described in U.S. Patent Nos. 10239971, 10202 471, 10787471 and U.S. Publication No. 2020 / 0362139, the descriptions of which are incorporated herein by reference. The bonding agents described here could be used to provide a modification of the hydrophobic surface of silica (pre-bonded or pre-treated silica) before using it in one of the processes described here.It should be noted that any combination of additional elastomers, additives and composites can be added to the elastomeric composite, for example in a mixer.

[0098] Another option is to carry out the mixing (for example, when the feedstock includes silica and / or silicon-treated carbon black) without tackifiers. Optionally, a coating agent (feedstock coating agent) may be introduced at any stage (or at several stages or locations) before discharge. Mixing processes without tackifiers and / or with coating agents, including exemplary coating agents, are described in PCT Publication No. WO 2022 / 125675, the description of which is incorporated herein by reference.

[0099] The total charge rate (single charge or mixture of charges) can be at least 20 phr, at least 30 phr or at least 40 phr. Optionally, the total charge rate can be between 20 phr and 250 phr, between 30 phr and 250 phr, between 30 phr and 200 phr, between 30 phr and 180 phr, between 30 phr and 150 phr, between 30 phr and 100 phr, between 30 phr and 90 phr, between 30 phr and 80 phr, between 30 phr and 70 phr, between 30 phr and 65 phr, between 30 phr and 60 phr, between 30 phr and 50 phr, between 40 phr and 250 phr, between 40 phr and 200 phr, between 40 phr and 180 phr, between 40 phr and 150 phr, between 40 phr and 100 phr, between 40 phr and 90 phr, between 40 phr and 80 phr, between 40 phr and 70 phr, between 40 phr and 65 phr, or between 40 phr and 60 phr.

[0100] In some embodiments, at least 50% of the filler (for example, at least 75% or at least 90% of the filler) is selected from carbon black and materials coated and treated with it. In some embodiments, at least 50% of the filler (for example, at least 75% or at least 90% of the filler) consists of silica. In some embodiments, at least 50% of the filler (for example, at least 75% or at least 90% of the filler) consists of silicon-treated carbon black. By way of example, the carbon black may be dispersed in the elastomer at a rate of between 30 phr and 200 phr, between 30 phr and 70 phr, or between 40 phr and 65 phr, or between 40 phr and 60 phr.As a more specific example, the elastomer being natural rubber alone or with one or more other elastomers, and the filler being carbon black alone or with one or more other fillers (for example, silica or silicon-treated carbon black), the carbon black can be dispersed in the natural rubber at a rate of between 30 phr and 70 phr, or between 40 phr and 65 phr, or between 40 phr and 60 phr.

[0101] In some embodiments, an amount of at least 50% of the filler (for example, at least 75% or at least 90% of the filler) is selected from silica. The amount of silica present in the elastomer composite formed can be between 20 phr and 250 phr, between 20 phr and 200 phr, between 20 phr and 150 phr, between 20 phr and 100 phr, between 30 phr and 150 phr, between 30 phr and 100 phr, between 25 phr and 100 phr, between 25 phr and 80 phr, between 35 phr and 115 phr, between 35 phr and 100 phr, between 40 phr and 110 phr, between 40 phr and 100 phr, between 40 phr and 90 phr, between 40 phr and 80 phr, and similar ranges. Filler mixtures containing silica may include 10% by weight of carbon black and / or silicon-treated carbon black.

[0102] The amount of silicon-treated carbon black present in the elastomer composite formed can be between 20 phr and 250 phr, between 20 phr and 200 phr, between 30 phr and 150 phr, between 40 phr and 100 phr, or between 50 phr and 65 phr.

[0103] The mixing of a wet filler with a solid elastomer is described in PCT Publication No. WO 2020 / 247663, the description of which is incorporated herein by reference. In the dry state, the fillers may contain no amount or only small amounts Amounts of liquid (e.g., water or moisture) adsorbed onto their surface. For example, carbon black may contain 0% by weight, or 0.1% to 1% by weight, or up to 3% by weight, or up to 4% by weight of liquid, and precipitated silica may have a liquid content (e.g., water or moisture) of between 4% and 7% by weight, for example, between 4% and 6% by weight. These fillers are referred to here as "dry fillers" or "unwetted fillers." A "wet filler" comprises a filler and liquid present on a substantial part or nearly all of the filler's surfaces, which may include internal surfaces or pores accessible to the liquid. Thus, a sufficient amount of liquid is provided to wet a substantial part or nearly all of the filler's surfaces before mixing with the solid elastomer.

[0104] The wet charge may have a liquid content of at least 15% by weight relative to the total weight of the wet charge, for example at least 20%, at least 25%, at least 30%, at least 40%, at least 50% by weight, or from 15% to 99%, from 15% to 95%, from 15% to 90%, from 15% to 80%, from 15% to 70%, from 15% to 60%, from 15% to 70%, from 15% to 60%, from 15% to 9 ... % to 65%, from 20% to 99%, from 20% to 95%, from 20% to 90%, from 20% to 80%, from 20% to 95%, from 20% to 9 ... % to 70%, from 20% to 60%, from 30% to 99%, from 30% to 95%, from 30% to 90%, from 30 % to 80%, 30% to 70%, 30% to 60%, 40% to 99%, 40% to 95%, 40% % to 90%, from 40% to 80%, from 40% to 70%, from 40% to 60%, from 45% to 99%, from 45% % to 95%, 45% to 90%, 45% to 80%, 45% to 70%, 45% to 60%, 50% % to 99%, 50% to 95%, 50% to 90%, 50% to 80%, 50% to 70% or 50% 60% to 100% by weight, relative to the total weight of the wet filler. At these quantities, the wet filler retains the form of a powder, particles, granules, cake, or paste, or a similar consistency and / or has the appearance of a powder, particles, granules, cake, or paste. In some embodiments, the wet filler is not a filler suspension and does not have the consistency of a liquid or suspension.

[0105] During mixing, at least some of the liquid can also be removed by evaporation as the wet filler is dispersed in the solid elastomer, and the filler surfaces can then become available to interact with the solid elastomer. The liquid in the wet filler can thus be removed by evaporation (and at least some of it can be removed under the described mixing conditions) and can be a volatile liquid, for example, volatile at the bulk mixture temperature. The volatile liquid can be, or may include, water, for example, at least 50% by weight water, at least 75% by weight water, at least 90% by weight water, at least 95% by weight water, or at least 99% by weight water. For example, the liquid may have a boiling point at 1 atm of 180 °C. In some embodiments, the wet filler has the consistency of a solid. Optionally, a filler The dry material is moistened only to such an extent that the resulting wet material retains the form of a powder, particles, granules, cake, or paste, or a similar consistency and / or appearance. The wet material does not flow like a liquid (at zero applied stress). Optionally, the wet material can retain its shape at 25°C when molded into such a form, whether as individual particles, agglomerates, granules, cakes, or pastes. EXAMPLES

[0106] The examples demonstrate the use of a mixer equipped with a ventilation system as described herein. Specifically, the mixer was a BB-16 tangential mixer (“BB-16”; of Kobelco Kobe Steel Group) equipped with two 6-bladed tangential rotors (type 6WI), providing a capacity of 14.4 L. The BB-16 mixer was equipped with an inlet pipe 140 and an outlet pipe 150, as illustrated in [Fig. 1]. A gas (air) was supplied to the plunger space 120 through the inlet pipe and exited the plunger space through the outlet pipe. The mixer was further equipped with a variable-speed fan, operating as a ventilation device 180, and a dust filter 160.The airflow through the piston-plunger space was determined by two factors: (a) the cross-sectional area of ​​the outlet pipe, Aoutlet (0.01824 m² based on a 6-inch diameter pipe), and (b) the gas velocity through the outlet pipe, Voutlet (m / s), regulated by the fan speed. The gas flow rate (Nm³ / h) was calculated from the following equation, normalized as a function of temperature (Toutlet = outlet pipe temperature): Flow rate = (Output A x Output Velocity) x (273.15K / (273.15K + Output T)) x 3600

[0107] The elastomeric composites were prepared by mixing natural rubber (STR20) with a wet carbon black filler or a mixture of wet carbon black and wet precipitated silica in a BB-16 mixer equipped with a ventilation system. For the entire mixture, the total filler content was set at 55 phr (carbon black alone) and 50 phr (carbon black / silica mixture). The wet carbon black filler was prepared by grinding Propel® E7 carbon black (Cabot Corporation) and re-wetting it in a pin granulator, resulting in a moisture content of approximately 57%. The wet precipitated silica (ZEOSIL® 1165MP, Solvay USA Inc.) was also prepared in a pin granulator; however, the dry precipitated silica filler was not ground prior to granulation. The natural rubber used was STR20 standard quality natural rubber (Thailand).Technical descriptions of these natural rubbers are widely available, notably in the Blue Book of Rubber magazine. World published by Lippincott and Peto, Inc. (Akron, Ohio, USA). The different formulations are listed in Table 1. [Tables 1] Example NR (phr) BR (phr) Carbon black (ph hr) Silica (ph hr) Flow rate through piston-plunger gap (Nm3 / h) Free water (%) *estimate Ex. 1-1 100 0 56 0 469 4.44-8.88* Ex. 1-2 100 0 56 0 572 4.43-8.87* Ex. 1-3 100 0 56 0 662 0.87 Ex. 1-4 100 0 56 0 746 0.00 Ex. 1-5 100 0 56 0 812 0.00 Ex. 1-6 10 0 56 0 1281 0.00 Ex. 2-1 80 20 56 0 2-4 80 20 56 0 752 2.06 Ex. 2-5 80 20 56 0 824 0.87 Ex. 2-6 80 20 56 0 1221 0.00 Ex. 3-1 100 0 36 15 445 0.00 Ex. 3-2 10 0 36 15 692 0.00

[0108] Mixing was performed with power PID control after each addition of the load. The proportional constant was 7.5%, the integral constant was 0.3 s, and no derivative control was used. The power setpoint varied between 50 kW and 90 kW depending on the mixing stage, and the maximum output of the power PID control loop was set to 100 rpm. The power input signal used by the power PID control loop was filtered using a Kalman filter with a K2 constant of 0.005 (see Appendix 1). The control system performed these calculations approximately every 0.2 s. The conditions of the first stage were: TCU temperature = 90 °C; fill factor = 66%; plunger pressure = 120 psig. The mixing protocol is shown in Table 2. [Tables 2] Step Description Duration (s) Temp P (°C) Plunger Position RPM Power Setpoint RPM (min) RPM (max) 1 Add 50% polymer - 75% charge - then the remaining 50% polymer - - High 40 - - 2 Mix until target time or temperature is reached 20 Low 40 - - 3 Mix under PID power control up to 125°C * Low PID power 90 50 100 4 Reduce speed 10 - High 20 - - 5 Add the remaining 25% charge 20 - High 20 - - 6 Mix under PID control 20 Low PID power 50 40 60 7 Mix under PID control PID control of power until the indicated temperature is reached ** Low PID of power 60 40 100 8 Mix under PID control of power until the indicated temperature is reached *** Low PID of power 90 50 100 9 Drain the mixer and close the hinged door 15 - Floating 20 - - *130 °C for example 1; 125 °C for example 2; 145 °C for example 3 **125 °C for examples 1 and 2; 135 °C for example 3 ***150 °C for example 1; 145 °C for example 2; 137 °C for example 3

[0109] Once the composite was evacuated, all the evacuated free water was collected along with the evacuated composite. The free water was filtered and weighed to determine the quantity of free water as a function of the ventilation flow rate. In some cases, free water remained in the plunger-piston space, and the quantity of this free water was estimated. The results are presented in Table 1, in which the quantity of free water is shown relative to the total weight of the composite.

[0110] In general, it can be observed that increasing the gas flow rate through the plunger gap decreases the amount of free water discharged from or remaining in the plunger gap. No free water was observed when the filler contained silica for the evaluated gas flow rates. Without adhering to any particular theory, the gas flow rate for fillers containing silica may be reduced due to the hygroscopic nature of silica, which allows for a more gradual release of water. These examples demonstrate that allowing gas flow through the plunger gap can result in a relatively dry elastomer composite in a first-phase (or single-phase) mixture when the elastomer and filler are mixed in the presence of a liquid (e.g., a wet filler).

[0111] The terminology used in this specification is intended to describe particular embodiments and is not meant to be restrictive. The terms "a," "an," "the," and "the" also include the plural forms unless otherwise clearly stated. The terms "includes" and / or "comprising," when used in this specification, denote the presence of the indicated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, and / or components.

[0112] With respect to the foregoing description, it is understood that modifications may be made to the details, particularly concerning the construction materials used and the shape, size, and arrangement of the parts or elements, without departing from the scope of this disclosure. This specification and the embodiments are exemplary only; the actual scope and intent of the disclosure are indicated by the following claims.

[0113] Annex 1: Description of the Kalman filter Variables: P = process variable (to be filtered by the control system) E = filtered estimate of P (calculated by the control system for each time increment of x) R = rate of change of P over time (calculated by the control system for each time increment of x) t = duration x = increment of time used by the control system (for data entry, (calculations and data output) K2 = filtering constant entered by the user in the control system Kl = filtering constant calculated from K2 Working equations: Kl = 2 (K2)**0.5 - K2 Et = Et-x + Rt-x + Kl (Pt - Et-x - Rt-x) Rt = Rt-x + K2 (Pt - Et) Remarks : Initial estimates of E and R must be made (values ​​of 0 are often acceptable). K2 is empirically selected by the user in order to obtain the desired filtering of P.

Claims

Demands

1. A method for preparing an elastomeric composite, comprising: (a) filling a mixing chamber of a batch elastomer mixer with at least one elastomer and a filler through a plunger-piston enclosure;(b) mixing the elastomer and the filler in the mixing chamber, which includes: (i) rotating one or more rotors disposed in the mixing chamber, (ii) moving a plunger through a plunger gap into the mixing chamber to push the elastomer and the filler in the plunger gap downwards into the mixing chamber, the plunger gap being defined by the plunger gap, and (iii) directing a gas stream through the plunger gap from a vent inlet to a vent outlet disposed in the plunger gap, the gas stream passing through the plunger gap and carrying away at least a portion of the vapor resulting from the mixing; and (c) evacuating the elastomer composite from the mixing chamber.

2. A method according to claim 1, wherein the minimum flow rate of the gas flow through the piston-plunger space is at least 200 Nm3 / h.

3. A method according to claim 1, wherein the minimum flow rate of the gas flow through the piston-plunger space is at least 400 Nm3 / h.

4. A method according to claim 1, wherein the minimum flow rate of the gas flow through the piston-plunger space is between 200 Nm3 / h and 6000 Nm3 / h.

5. A method according to any one of claims 1 to 4, wherein the flow rate is an average flow rate.

6. A method according to any one of claims 1 to 5, wherein the gas flow is continuous.

7. A method according to any one of claims 1 to 5, wherein the gas flow is pulsed.

8. A method according to any one of claims 1 to 7, further comprising a venting device in gaseous communication with the mixer, the venting device being configured to direct the gas so that it flows from the vent inlet to the vent outlet from the plunger-piston space through the vent outlet.

9. Method according to claim 8, wherein the ventilation device is selected from a fan, a blower, a gas pump, a compressor, an ejector and a venturi-type diffuser.

10. Method according to claim 8 or 9, wherein the ventilation device is disposed at one or more of the vent inlet and vent outlet.

11. A method according to claim 8 or 9, wherein the venting device is disposed at the vent outlet and is configured to draw gas from the plunger-piston space into the vent outlet.

12. A method according to any one of claims 8 to 11, further comprising, during mixing, a controller configured to: detect, via a pressure sensor, a pressure in the plunger space, and control the venting device so that the pressure in the plunger space is at negative pressure.

13. A method according to claim 12, wherein the controller is configured to adjust a flow of gas directed by the venting device so as to maintain the piston-plunger space at negative pressure.

14. A method according to claim 12, wherein the controller is configured to adjust a flow of gas directed by the ventilation device as a function of the mixer power.

15. A method according to any one of claims 1 to 14, wherein the vent inlets or vent outlets may be circular, oval, rectangular or square in shape.

16. A method according to any one of claims 1 to 15, further comprising selectively opening one or more of the vent inlet and vent outlet.

17. A method according to any one of claims 1 to 16, further comprising opening one or more of the vent inlet and vent outlet during a mixing and operation close one or more of the vent inlet and vent outlet during filling.

18. A method according to any one of claims 1 to 17, further comprising blocking the vent outlet with a gate valve for the vent outlet while the plunger piston is arranged vertically at or above the vent outlet.

19. A method according to any one of claims 1 to 18, wherein the vent inlet and vent outlet are arranged on opposite side walls of the plunger-piston housing.

20. A method according to any one of claims 1 to 18, wherein the vent inlet and vent outlet are arranged side by side on a wall forming the plunger-piston enclosure.

21. A method according to any one of claims 1 to 20, wherein: the vent inlet and vent outlet are located in an upper part of the plunger housing; the vent inlet and vent outlet are located in a lower part of the plunger housing; the vent inlet is located in an upper part of the plunger housing and the vent outlet is located in a lower part of the plunger housing; or the vent inlet is located in a lower part of the plunger housing and the vent outlet is located in an upper part of the plunger housing.

22. A method according to any one of claims 1 to 21, wherein the vent inlet is located in a lower part of the plunger housing and the vent outlet is located in an upper part of the plunger housing.

23. A method according to any one of claims 1 to 22, wherein the vent inlet has a total area greater than that of a vent outlet opening.

24. A method according to any one of claims 1 to 22, wherein the vent outlet has a total area greater than that of a vent inlet opening.

25. A method according to any one of claims 1 to 24, wherein the filling comprises filling the solid elastomer and the charge through a feed hopper gate disposed in the plunger housing.

26. Method according to claim 25, wherein the vent inlet is disposed above the feed hopper door.

27. ​​A method according to claim 25 or 26, wherein the plunger housing comprises a rear wall opposite the feed hopper door, the vent outlet being disposed in the rear wall of the plunger housing.

28. Method according to claim 27, wherein the vent inlet is disposed in the rear wall of the enclosure.

29. A method according to any one of claims 1 to 28, further comprising removing airborne particles from the plunger housing using a hood disposed above one or more of the vent inlet and vent outlet.

30. A method according to any one of claims 1 to 28, further comprising a filter or scrubber disposed between the vent outlet and the ventilation device.

31. A method according to any one of claims 25 to 30, further comprising removing airborne particles from the plunger housing using a hood disposed above the feed hopper door.

32. A method according to any one of claims 1 to 31, wherein the discontinuous elastomer mixer further comprises a vent outlet passage extending from the vent outlet.

33. Method according to claim 32, wherein the vent outlet passage extends at an upward angle from the vent outlet.

34. A method according to any one of claims 1 to 33, wherein the discontinuous elastomer mixer further comprises a vent inlet passage extending from the vent inlet.

35. A method according to any one of claims 1 to 34, wherein the mixing chamber further comprises a vent plunger disposed on the mixing chamber to provide additional ventilation.

36. A method according to any one of claims 1 to 35, wherein the feed is a wet feed comprising a liquid, at least a part of which evaporates during mixing to generate steam. 40

37. A method according to any one of claims 1 to 36, wherein the filling in step (a) further comprises filling the mixer with at least one binding agent.

38. A method according to any one of claims 1 to 36, wherein the filling of the charge in step (a) comprises filling the mixer with the charge contained in low melting point bags.