Extrusion processes for elastomeric compositions

Abstract

The invention relates to methods for processing a composition comprising an elastomer and a filler. The method includes processing the composition using a single-screw or twin-screw extruder having a die (330) with at least one non-circular slot (332) extending through the die body, wherein the non-circular slot (332) has a conical inner surface. The invention also relates to the extrudates resulting from the processing.

Description

Title of the invention: Extrusion processes for elastomeric compositions. FIELD OF THE INVENTION

[0001] The present invention relates generally to methods of processing elastomeric compositions, such as methods of processing an elastomeric composition through a die of an extruder. CONTEXT

[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 resulting composite (masterbatch), i.e., a premix of reinforcing material, elastomer, and / or various optional additives, 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 processing a composition, the process comprising: introducing the composition into a screw extruder, in which the composition comprises at least one elastomer and at least one filler; to force the composition through the extruder by applying a shear force to the composition; and extruding the composition through a fixed die provided at one end of the extruder outlet, wherein the extrusion comprises: force the composition through at least one non-circular slot extending through a die body of the fixed die from a first face of the die body to an opposite face of the die body which is opposite the first face, thus forming a passage such that the composition is forced through an inner surface of the at least one non-circular slot, in which the inner surface is conical such that a first opening at one of the first face or the opposite face is smaller than a second opening at the other of the first face or the opposite face.

[0004] Another aspect relates to a process for treating a composition, the process comprising: introduce the composition into a screw extruder, in which the composition comprises at least one elastomer and at least one filler; to force the composition through the extruder by applying a shear force to the composition; and extruding the composition through a fixed die provided at one end of the extruder outlet, wherein the extrusion comprises: force the composition through at least one slot extending through a die body of the fixed die from a first face of the die body to an opposite face of the die body that is opposite the first face, thus forming a passage such that the composition is forced through an inner surface of the at least one slot, in which the inner surface is conical such that a first opening at one of the first or opposite faces is smaller than a second opening at the other of the first or opposite faces, and in which the first and second openings are non-concentric.

[0005] Another aspect relates to a process for treating a composition, the process comprising: introducing the composition into a screw extruder, wherein the composition comprises at least one elastomer and at least one filler having a filler ratio of at least 20 phr, wherein the composition is substantially free from rubber chemicals; force the composition through the extruder by applying a shear force to the composition; extruding the composition through a die provided at one outlet end of the extruder, the die comprising a die body having a first face and an opposite face, wherein the extrusion comprises passing the composition through at least one slot extending through the die body from the first face to the opposite face which forms a passage; and cut the extradied composition using an associated blade of the die, in which one or more of the die and the associated blade is rotating.

[0006] Another aspect relates to a process for treating a composition, the process comprising: introducing the composition into a screw extruder, wherein the composition comprises at least one elastomer and at least one filler having a filler ratio of at least 20 phr, and the composition has a dynamic storage modulus of at least 900 kPa measured at a strain amplitude of 0.3% G'(0.3%) at a frequency of 1 Hz and at 100 °C; force the composition through the extruder by applying a shear force to the composition; extruding the composition through a die provided at one outlet end of the extruder, wherein the die comprises a die body having a first face and an opposite face, wherein the extrusion comprises passing the composition through at least one slot extending through the die body from the first face to the opposite face which forms a passage; and cut the extradied composition using an associated blade of the die, in which one or more of the die and associated blade is rotating.

[0007] Another aspect relates to a process for treating a composition, the process comprising: introduce the composition into the screw extruder, in which the composition comprises at least one elastomer and at least one filler; to force the composition through the extruder by applying a shear force to the composition, wherein the screw or screws of the extruder each comprise (i) a shaft having a longitudinal axis, a first end, and a second outlet end, and (ii) a screw thread provided on the shaft along the longitudinal axis from the first end to the second outlet end for applying the shear force to the composition; and extrude the composition through a die provided at the second outlet end of each screw or screws of the extruder, wherein the second outlet end has an end portion with a flat face formed by the shaft and the screw thread, and wherein the flat face has an area between 20% and 70% of an area defined by an outside diameter of the screw thread.

[0008] Another aspect relates to a process for treating a composition, the process comprising: introduce the composition into a screw extruder, in which the composition comprises at least one elastomer and at least one filler; to force the composition through the extruder by applying a shear force to the composition, wherein the screw or screws of the extruder each comprise (i) a shaft having a longitudinal axis, a first end, and a second outlet end, and (ii) a screw thread provided on the shaft along the longitudinal axis from the first end to the second outlet end for applying the shear force to the composition; and extrude the composition through a die provided at the second outlet end of the screw or screws, wherein the second outlet end has an end portion with a flat face formed by the screw shaft and thread, and wherein at least a portion of the flat face is configured to have an area between 0.9 and 3 times the area of ​​a slot in an extruder die.

[0009] In some embodiments, the composition or composite comprises an elastomer and a filler with a filler content of at least 20 phr. In some embodiments, the composition or composite is substantially free of rubber chemicals. In some embodiments, the composition or composite has a filler content of at least 20 phr, and the composition or composite has a dynamic storage modulus of at least 900 kPa measured at a strain amplitude of 0.3%, G'(0.3%), at a frequency of 1 Hz and at 100 °C. In some embodiments, the extruder and / or die are configured so that the composition has a length between 20 mm and 150 mm and a thickness between 2 mm and 20 mm. In some embodiments, the composition is an elastomeric composite.

[0010] In some embodiments, the composition or composite has a liquid content of between 0.3% and 10%.

[0011] In some embodiments, the screw extruder is a single-screw or twin-screw extruder. In some embodiments, the extruder is a twin-screw extruder and comprises twin screws forming a pair of meshed screws. In some embodiments, the extruder is a twin-screw extruder and comprises twin screws tapered towards each other. In some embodiments, the screw or screws are configured to heat and / or cool the elastomer material.

[0012] In some embodiments, an inner surface of the slot is conical such that a first opening on one of the first or opposite faces is smaller than a second opening on the other of the first or opposite faces. The first and second openings may be concentric or non-concentric. In some embodiments, the first opening is located on the first face so that the slot is outwardly conical. In some embodiments, the first opening is located on the opposite face so that the slot is conical inwards. In some embodiments, the conicity of the inner surface of at least one slot is configured to maintain the composition on a cutting edge of at least one slot which aligns substantially with a direction of a vector combining tangential and radial forces imposed on the composition extruded through the die.

[0013] In some embodiments, at least one wall of the inner surface of the slot is substantially flat, concave, or convex. In some embodiments, at least one wall of the conical inner surface of at least one slot is beveled. In some embodiments, a cross-section of the inner surface of the slot defines a taper angle between 20° and 60°, for example, between 20° and 50°.

[0014] In some embodiments, the at least one slot defines an open surface covering 20% ​​to 60% of the total surface area of ​​the first face or the opposite face. In some embodiments, the at least one slot has a radial length-to-circumferential-width ratio of between 1.1:1 and 10:1, and preferably between 1.5:1 and 4:1, and more preferably between 2:1 and 3:1.

[0015] In some embodiments, at least one slot is configured to align substantially with a direction of a vector combining tangential and radial forces on the composition extruded through the die from the extruder. In some embodiments, at least one slot has an elongated shape. In some embodiments, at least one slot has an elliptical or oval shape. In some embodiments, at least one of the first and second openings of at least one slot has a stadium shape with two parallel linear edges. In some embodiments, a centerline aligned with the longest dimension of at least one slot is offset from an axial axis of a corresponding screw of the extruder.In some embodiments, a centerline aligned with the longest dimension of at least one slot is offset from an axial axis of a corresponding extruder screw by an angle between 20° and 50°, for example, between 20° and 45°, or between 20° and 40°, or between 25° and 50°, or between 25° and 45°, or between 25° and 40°, or between 30° and 50°, or between 30° and 45°, or between 30° and 40°. In some embodiments, at least one slot is kidney-shaped. In some embodiments, at least one slot has at least one wavy or serrated cutting edge. In some embodiments, at least one slot has at least one straight cutting edge. In some embodiments, the associated blade has at least one linear, circular, wavy, or serrated edge. In some embodiments, the associated blade is at least one edge of at least one opening of the die.

[0016] In some embodiments, the at least one slot comprises a plurality of slots. In some embodiments, a number of sets of the plurality The number of slots corresponds to a number of screws provided in the extruder. In some embodiments, a midpoint of each set of the plurality of slots is substantially coaxially aligned with the corresponding screw provided in the extruder. In some embodiments, at least one slot comprises between 1 and 100 slots, and preferably between 2 and 100 slots, and more preferably between 4 and 40 slots. In the method according to claim 30, the associated blade is external to the die and configured to cut the extruded composition as the extruded composition exits the die.

[0017] Some embodiments further include a heating element for heating the composition extruded through the die, wherein the heating element is configured to be heated to a temperature between 90 °C and 150 °C, for example between 110 °C and 150 °C, or between 130 °C and 150 °C. In some embodiments, the clearance between the die and the screw extruder is between 0.5 mm and 5.0 mm, for example between 0.8 mm and 2.0 mm, or between 1.0 mm and 2.0 mm. In some embodiments, the flow of the composition through the extruder occurs at a rate between 0.0005 m³ / min and 1.0 m³ / min. In some embodiments, the flow of the composition through the extruder occurs at a flow rate between 0.5 kg / min and 1,000 kg / min, in which the density of the extrudate is between 0.90 and 1.3.In some embodiments, the composition is extruded through the outlet end at an outlet speed between 0.05 m / min and 30 m / min, for example, between 0.1 m / min and 30 m / min, or between 0.1 m / min and 16 m / min. In some embodiments, the extruder screw or twin screws rotate at a speed between 5 rpm and 50 rpm. In some embodiments, the extruder is configured to maintain a metal temperature of the single-screw or twin-screw extruder between 50 °C and 150 °C.

[0018] In some embodiments, the screw is conical and the surface area of ​​the flat face is between 20% and 70% of the surface area defined by the maximum outside diameter of the screw thread. In some embodiments, the screw is conical and the surface area of ​​the flat face is between 20% and 70% of the surface area defined by the outside diameter of the screw thread at the second exit end. In some embodiments, the surface area of ​​the flat face is between 20% and 70% of the surface area defined by the outside diameter of the screw thread, or is between 20% and 60% of the surface area defined by the outside diameter of the screw thread, or is between 20% and 50% of the surface area defined by the outside diameter of the screw thread, or is between 20% and 40% of the surface area defined by the outside diameter of the screw thread.

[0019] In certain embodiments, the flat face of the screw has a geometry having a circular part and a wedge-shaped part which is at least partially formed by the screw thread, wherein one dimension of the wedge-shaped portion relative to the center of the circular portion is at least 70% of a radius formed by the widest dimension of the screw thread. In some embodiments, the wedge-shaped portion defines a sector having an angle between 20° and 100°.

[0020] In certain embodiments, at least a portion of the flat face is configured to align with the slot such that at least a portion of the flat face covers the entire slot of the die with each rotation of the screw. In certain embodiments, at least a portion of the flat face has an area between 0.9 and 2 times the area of ​​the slot, or between 0.9 and 1.5 times the area of ​​the slot.

[0021] In some embodiments, the thickness of the end part having the flat face is between 5 mm and 15 mm.

[0022] In some embodiments, the end part of a screw having the flat face is formed by a truncation of the second end of the shaft.

[0023] In certain embodiments, the screw or screws of the extruder each comprise (i) a shaft having a longitudinal axis, and (ii) a screw thread provided on the shaft along the longitudinal axis, in which, near the exit end of the extruder, there is an end portion of the screw or screws having a flat face formed by the shaft and the screw thread, and in which the flat face has an area between 20% and 70% of an area defined by an outside diameter of the screw thread.In some embodiments, the screw or screws of the extruder each comprise (i) a shaft having a longitudinal axis, and (ii) a screw thread provided on the shaft along the longitudinal axis, wherein, near the exit end of the extruder, there is an end portion of the screw or screws having a flat face formed by the shaft and the screw thread, and wherein the flat face is configured to have an area between about 0.9 and 3 times the area of ​​at least one slot.

[0024] Another aspect relates to a process for processing a composite in an integrated manufacturing operation, comprising: Introducing the composite into a screw extruder; to force the composite through the extruder by applying a shear force to the composition; and extrude the composite through a die provided at one end of the extruder so that the extruded composite has an irregular shape.

[0025] Another aspect relates to a method of extruding a material, the method comprising: introducing the material into a screw extruder; force the material through the extruder by applying a shear force to the material; extrude the material through a die plate provided at one end of the extruder's outlet, in which the elastomeric extrudate has an irregular shape, in which the extrudate has an angle of curvature in at least one dimension between 50° and 160°, and in which the length of the extrudate is not greater than 500 mm.

[0026] Another aspect concerns an extrudate resulting from any process described here.

[0027] In some embodiments, the extrudate is substantially free of rubber chemicals. In some embodiments, the extrudate has a dynamic storage modulus of at least 900 kPa measured at a strain amplitude of 0.3%, G'(0.3%), at a frequency of 1 Hz and at 100 °C, and preferably between 900 kPa and 3000 kPa at a frequency of 1 Hz and at 100 °C.

[0028] In certain embodiments, the composition, composite or extrudate essentially consists of: (i) at least one elastomer and at least one filler, or (ii) at least one elastomer, at least one filler and at least one anti-degrading agent, or (iii) at least one elastomer, at least one filler and at least one tackifying agent, or (iv) at least one elastomer, at least one filler, at least one anti-degrading agent and at least one tackifying agent.

[0029] In certain embodiments, the composition, composite or extrudate consists of: (i) at least one elastomer and at least one filler, or (ii) at least one elastomer, at least one filler and at least one anti-degrading agent, or (iii) at least one elastomer, at least one filler and at least one tackifying agent, or (iv) at least one elastomer, at least one filler, at least one anti-degrading agent and at least one tackifying agent.

[0030] Another aspect relates to an elastomeric extrudate comprising at least one elastomer and at least one filler in an amount of at least 20 phr, in which the extrudate has: a length not exceeding 500 mm; and an angle of curvature in at least one dimension between 50° and 160°.

[0031] In some embodiments, the extrudate has a main body portion having a curvature angle in at least one dimension of between 50° and 160°. In some embodiments, the extrudate further comprises a width, in which the aspect ratio between the length and width of the extrudate is between 1.5:1 and 5:1. In some embodiments, the curvature angle is in at least two dimensions. In some embodiments, the extrudate has a spoon-like shape. In some embodiments, the extrudate has a thickness of between 2 mm and 25 mm, preferably between 2 mm and 20 mm, and preferably between 5 mm and 15 mm. In some embodiments, the width of the extrudate is between 20 and 300 mm, or between 20 and 150 mm, or between 20 and 75 mm. In some embodiments, the extrudate has a surface area of ​​between 0.0005 and 0.01 m2, and preferably between 0.0005 and 0.007 m2.

[0032] In some embodiments, at least one elastomer is selected from natural rubber, functionalized natural rubber, styrene-butadiene rubber, functionalized styrene-butadiene rubber, polybutadiene rubber, functionalized polybutadiene rubber, polyisoprene rubber, ethylene-propylene rubber, isobutylene-based elastomers, halogenated butyl rubber, polychloroprene rubber, nitrile rubber, hydrogenated nitrile rubber, polysulfide rubber, polyacrylate elastomers, fluoroelastomers, perfluoroelastomers, silicone elastomers, and mixtures thereof. In some embodiments, the elastomeric extrudate comprises at least 50% natural rubber. In some embodiments, the elastomeric extrudate further comprises at least one of styrene-butadiene rubber and polybutadiene rubber.

[0033] In some embodiments, at least one filler is selected from carbon black, carbonaceous materials, silica, nanocellulose, lignin, clays, nanoclays, metal oxides, metal carbonates, pyrolysis carbon, graphene, graphene oxides, reduced graphene oxide, carbon nanotubes, single-walled carbon nanotubes, multi-walled carbon nanotubes, carbon nanostructures, fragments of carbon nanostructures or fractured multi-walled carbon nanotubes, or combinations thereof, and materials coated and treated with them. In some embodiments, the filler is selected from carbon black, silica, silicon-treated carbon black, and combinations thereof. In some embodiments, the filler is carbon black. In some embodiments, the filler is silica.In some embodiments, the filler is a mixture comprising carbon black and silica.

[0034] In some embodiments, the elastomeric extrudate is formed by extruding an elastomeric composition through a screw extruder, which may be a single screw or twin screw extruder.

[0035] In certain embodiments, the single-screw or twin-screw extruder is configured to expel the material by applying a shear force to the material, the extruder further comprising: a die provided at the outlet end of the single-screw or twin-screw extruders for extruding the material, wherein the die comprises: a fixed die body, a first face of the main body of the supply chain, an opposite face of the die body that is opposite the first face, and at least one slot extending through the die body from the first face to the opposite face, thus forming a passage, in which at least one slot has an inner surface that is conical such that a first opening at one of the first face or the opposite face is smaller than a second opening at the other of the first face or the opposite face, in which at least one slot is configured to align substantially with a direction of a vector combining tangential and radial forces imposed on the material extruded through the die from the extruder.

[0036] Another aspect concerns a plurality of elastomeric extrudates comprising an extrudate resulting from any process described here.

[0037] Another aspect relates to a plurality of elastomeric extrudates, each having an irregular shape and comprising at least one elastomer and at least one filler in an amount of at least 20 phr, wherein: at least 75% of the plurality of extrudates have a length not exceeding 500 mm; and at least 75% of the plurality of elastomeric extrudates have a curvature angle in at least one dimension between 50° and 160°.

[0038] In some embodiments, at least 90% of the plurality of extrudates have a curvature angle in at least one dimension between 50° and 160°. In some embodiments, at least 75%, and preferably at least 80%, and more preferably at least 90% of the plurality of extrudates have a width in which the aspect ratio between the length and the width of the extrudate is between 1.5:1 and 5:1.

[0039] Another aspect relates to a ball comprising the plurality of elastomeric extrudates as described herein, in which the ball has a void volume of between 50% and 90%. Brief description of the drawings

[0040] Reference is made here to the accompanying drawings which form an integral part of this disclosure and which illustrate embodiments in which the systems and processes described in this specification can be implemented.

[0041] The [Fig. 1] is an illustrative embodiment of an extruder according to the present disclosure.

[0042] The [Fig.2] is an illustrative embodiment of a twin-screw extruder according to the present disclosure.

[0043] Fig. 3A, Fig. 3B and Fig. 3C illustrate a die for an extruder, according to one embodiment.

[0044] Fig. 4A and Fig. 4B illustrate a die for an extruder, according to another embodiment.

[0045] Fig. 5 illustrates a die for an extruder, according to yet another embodiment.

[0046] Figs. 6A, 6B and 6C illustrate an embodiment of a screw for an extruder, according to one embodiment.

[0047] Figures [Fig.7A], [Fig.7B] and [Fig.7C] illustrate an embodiment of another screw for an extruder, according to one embodiment.

[0048] Fig. 8A illustrates the parameters for determining the angle of curvature.

[0049] Fig.8B, Fig.8C and Fig.8D are a schematic illustration of an extrudate according to one embodiment.

[0050] Fig. 9 is a schematic illustration of a ball formed from the extrudate according to one embodiment.

[0051] Fig. 1OA and Fig. 1OB are photographs of extrudates formed by extruding elastomeric composites of a first phase (Fig. 1OA) and a second phase (Fig. 1OB) through a die plate of Figures 3A to 3C.

[0052] Representative extrudates prepared for image analysis are shown in the photographs of [Fig. 11 A] (1st phase) and [Fig. 11 B] (2nd phase).

[0053] [Fig.12A] (first phase) and [Fig.12B] (second phase) are contours of the extrudates of figures 11A and 11B, respectively.

[0054] [Fig.13A] and [Fig.13B] are ellipses corresponding respectively to the contours of figures 12A and 12B.

[0055] Identical reference numbers represent identical parts in the whole document. DETAILED DESCRIPTION

[0056] The present invention relates to methods and apparatus for processing a composition, for example, by extruding an elastomeric material. In one aspect, the disclosure relates to a method for processing a composition through a die of an extruder, which can result in the formation of discrete pieces ("extrudates") having uniform or substantially uniform sizes and / or discrete pieces having a curved shape. Another aspect provides a plurality of extrudates comprising discrete pieces and / or pieces having a curved shape, which can result in a ball having higher void fractions.

[0057] Although there are various systems and processes for extruding an elastomeric material into extrudates, for example pellets, granules or the like, The processes and apparatus described herein are intended for processing an elastomeric composition, for example, a composition comprising an elastomer and a filler. In some cases, certain composites are strong (for example, they have a high dynamic storage modulus) and can be difficult to process, for example, to cut into substantially uniform pieces, using existing or conventional twin-screw rollers (TSRs) and fixed-knife devices. As such, the processes and apparatus described herein are intended for processing and supplying extruded compositions of discrete sizes exhibiting substantial uniformity in terms of size and / or shape, and / or for extruding a composite. In some embodiments, the elastomeric composition is a composite that is substantially free of rubber chemicals.In some embodiments, the elastomeric composition has a dynamic storage modulus of at least 900 kPa measured at a strain amplitude of 0.3%, G'(0.3%). The amplitude G'(0.3%) is generally measured at a given frequency and pressure, for example, at a frequency of 1 Hz and a temperature of 100 °C. The measurement can be performed after preconditioning, for example, after 5 minutes of static conditioning, 10 shear cycles at 50% strain, and 30 minutes of recovery at 0.3% strain. In some embodiments, the elastomeric composite is formed from a mixture comprising at least a solid elastomer and a wet filler, wherein the wet filler comprises a liquid, or at least a solid elastomer, a filler, and a liquid (the filler and liquid being loaded separately into the mixer).In some embodiments, the elastomeric composite is formed from a filler suspension and an elastomer or elastomer source in liquid form, for example an elastomer solution, an emulsion, a latex, and the like.

[0058] One aspect of this disclosure relates to methods for processing an elastomeric composition using a screw extruder, for example, a single-screw or twin-screw extruder having a die provided at the extruder outlet. As used herein, the term "die" means a "die" or "die plate" provided in an end plate located at the outlet or discharge opening of an extruder, for example, at the discharge end, in which slots or openings extend through the end plate, forming a passage. In some embodiments, the slots or openings are formed as holes or slots milled or drilled through the outlet or the end plate of the extruder.In some embodiments, the die or die plate comprises a fixed die body that does not rotate, but is rather fixed so that the elastomer material is extruded through it. In other embodiments, the die can be rotary to cut the composition or material. elastomer. In some embodiments, at least one edge of the slot may be a cutting edge for cutting the composite into discrete pieces. In some embodiments, the die may have an associated blade (a "knife" is synonymous with a blade), which may be a cutting edge of the slot or may be external to the die, in which the die and / or the associated blade are rotatable.

[0059] In one aspect, the die is fixed. Accordingly, one aspect described herein relates to a process for processing a composition, comprising: introducing the composition into a screw extruder, which may be a single-screw or twin-screw extruder, wherein the composition comprises at least one elastomer and at least one filler; forcing the composition through the extruder by applying a shear force to the composition; and extruding the composition through a fixed die provided at an outlet end of the single-screw or twin-screw extruder, wherein the extrusion comprises: forcing the composition through at least one non-circular slot extending through a die body of the fixed die from a first face of the die body to an opposite face of the die body that is opposite the first face,forming a passage such that the composition is forced through an inner surface of at least one non-circular slot, wherein the inner surface is conical such that a first opening at one of the first or opposite faces is smaller than a second opening at the other of the first or opposite faces. In another aspect, extrusion comprises: forcing the composition through at least one slot extending through a die body of the fixed die from a first face of the die body to an opposite face of the die body that opposes the first face, thus forming a passage such that the composition is forced through an inner surface of at least one slot.in which the inner surface is conical such that a first opening at one of the first or opposite faces is smaller than a second opening at the other of the first or opposite faces, and in which the first and second openings are non-concentric.

[0060] In another aspect, the die is rotary and has an associated blade for cutting the extruded composition. Accordingly, the present disclosure relates to another method of processing a composition, comprising: introducing the composition into a screw extruder, wherein the composition comprises at least one elastomer and at least one filler having a filler content of at least 20 phr, wherein the composition may be substantially free of rubber chemicals and / or have a dynamic storage modulus of at least 900 kPa measured at a strain amplitude of 0.3%, G' (0.3%); and extruding the composition through the extruder by applying a shear force to the composition; extravaganza of the composition; extravaganza of the composition through a die provided at an exit end of the extruder, wherein the die comprises a die body having a first face and an opposite face, wherein the extrusion comprises passing the composition through at least one slot extending through the die body from the first face to the opposite face which forms a passage; and cutting of the extravaganza of the composition with an associated blade of the die, wherein one or more of the die and the associated blade are rotatable.

[0061] Figure 1 is an illustrative embodiment of an apparatus for processing a composition, such as a filled elastomeric material, for example, a composite. In some embodiments, the apparatus may be an extruder 100 for processing the elastomeric material; Figure 1 represents a single-screw extruder. The processing may involve cutting the elastomer into discrete pieces (as opposed to long sheets or tubes), for example, with dimensions less than 500 mm and / or into discrete pieces having an angle of curvature in at least one dimension (for example, two dimensions) of between 50 degrees and 160 degrees (50° to 160°), wherein the pieces are uniform or substantially uniform in terms of size and / or shape.The extruder 100 may include a hopper (not shown) connected to the extruder housing 110 for introducing the composition into the extruder (continuously or intermittently), a motor (not shown) that drives one or more screws 120 to force the composition through the extruder by applying a shear force, and a die 130 provided at an outlet end of the extruder 100 through which the elastomer material is extruded. In some embodiments, the extruder 100 may include a reduction mechanism mounted, for example, as a drive unit for driving the screw or screws 120.In some embodiments, where the screw or screws 120 comprise twin screws, one or more bevel gears (not shown) may be provided to drive the screw or screws 120, in which the driven screw or screws are rotated by meshing with the bevel gear(s). Although [Fig. 1] illustrates the extruder as an individual component for processing an elastomeric material, it is understood that this disclosure is not intended to be limiting. Rather, it is understood that the extruder 100 may be part of a larger mixing apparatus, which may include one or more mixers, the extruder(s) 100, one or more cutting devices, one or more dryers, one or more balers, rollers, or the like.It is further understood that the extruder 100 can also be supplied as a separate component / operation for the mixing unit or be supplied as part of the mixing unit, for example a single / integrated unit.

[0062] In some embodiments, each of the screw or screws 120 is provided inside the housing 110 and may include a shaft 122 having a longitudinal or axial axis, also called the "screw axis", SA, a first end 122A and a second output end 122B, and at least one helical screw thread 124, which is represented as a helical screw thread, provided on the shaft along the longitudinal axis between the first end 122A and the output end 122B.In some embodiments, the shaft 122 may have a cylindrical shape with a conical end; for example, the circumference at the output end 122B is narrower than at the first end 122A, and / or at least one helical screw thread 124 may be conical, wherein at least one helical screw thread 124 may have a variable pitch and / or outside diameter that gradually decreases from the first end 122A to the output end 122B of the shaft 122. For example, the shaft 122 may have a maximum outside diameter closer to the first end 122A that is larger than the outside diameter of the helical screw thread at the output end 122B. In some embodiments, the shaft 122 may have a conical shape in which at least one helical screw thread 124 may be provided with a constant width and / or pitch.It should be noted that, although the helical screw thread 124 is described here as a single helical screw thread, it is understood that the screw may have more than one helical screw thread, for example, a helical screw thread having a double helix design, or a double helix at least at the output end 122B. Furthermore, when the extruder 100 includes twin screws (or more than two screws), the screws may be configured so that the helical screw threads 124 of the twin screws are in a gear relationship, i.e., meshed; for example, the helical screw thread 124 overlaps the pitch of the other screw thread 124.Thus, the screw or screws 120 are configured to flow the elastomer material from the first end 122A to the output end 122B of the shaft 122 by applying a shear force on the elastomer material, when the elastomer material is introduced from the hopper, for example by gravity feeding.

[0063] The die 130 is provided at, near, or abutting the outlet end 122B of the shaft 122, for example, in an end plate provided at the outlet or discharge opening of the extruder 100, in which slots or openings extend through a body of the die forming a passage, so that the elastomer material is extruded through the die 130. Various embodiments of the die 130 are examined in more detail below and illustrated in Figures 3A to 5. In some embodiments, the slots or openings are formed as holes or slots (which may be of any closed shape, circular or non-circular) milled or drilled through the outlet or end plate of the extruder 100. In some embodiments, the The die comprises a fixed die body that does not rotate, but is rather fixed (for example, fixed relative to the housing 110) so that the elastomer material is extruded through it. In other embodiments, the die 130 may be rotatable.

[0064] Figure 2 is an illustrative embodiment of a twin-screw extruder. In some embodiments, the twin screws 220A, 220B are provided inside the housing 210 and each may comprise a shaft 222 having a longitudinal axis or screw axis "SA" and a first end 222A and a second output end 222B, and at least one helical screw thread 224 provided on the shaft along the longitudinal axis from the first end 222A to the second output end 222B. It should be noted that, although the helical screw thread 224 is described here as a single helical screw thread, it is understood that a screw having one or more helical screw threads may be used, for example, a helical screw thread in a twin-helix design.In one embodiment, the twin screws 220A, 220B are configured such that the helical screw threads 224 of the twin screws are in a gear relationship, i.e., meshed with each other; for example, one helical screw thread 224 overlaps the pitch of the other screw thread 224 in the opposite direction of rotation. Figure 2 further depicts the screws as being conical, i.e., tapered, towards each other. Thus, the twin screws 220A, 220B are configured to flow the elastomer material from the first end 222A to the second output end 222B of the shaft 222 by applying a shear force to the elastomer material when the elastomer material is introduced from the hopper.

[0065] The die 230 may be provided at, near, or abutting the second outlet end 222B of the shaft(s) 222, for example in an end plate provided at the outlet or discharge opening of the extruder 200, for example the outlet end, in which slots or openings extend through the end plate forming a passage, so that the elastomer material is extruded through the die 230. Various embodiments of the die 230 are examined in more detail below and illustrated in Figures 3A to 5. In some embodiments, the slots or openings are formed as holes or slots (which may be circular or non-circular) milled or drilled through the outlet or the end plate of the extruder 200.In some embodiments, the die comprises a fixed die body that does not rotate, but is rather fixed so that the elastomeric material is extruded through it.

[0066] Another aspect concerns a die designed to have a specific geometry or orientation which, contrary to expectations, proved capable of cutting the composite into smaller, discrete pieces, for example, whose sizes were less than 500 mm, and / or to have a curvature angle in at least one dimension (e.g., two dimensions) between 50 and 160 degrees. The pieces are of uniform or substantially uniform size and / or shape, so that the pieces can be used in subsequent processing, for example, by the end user or customer.In some embodiments, the processing and / or cutting of such composites was not previously feasible with conventional twin-screw roller (TSR) designs and fixed-knife devices, for example, composites with high strength that cannot be cut uniformly or substantially uniformly with current dies and processes, for example, composites that are substantially free of rubber chemicals and / or have a dynamic storage modulus of at least 900 kPa measured at a strain amplitude of 0.3%, G'(0.3%). Figures 3A to 5 illustrate various embodiments of a die, for example 330, 430, 530, which can be used at the outlet end of a single-screw or twin-screw extruder, for example 100, 200, to process a composition, and in particular to extrude the elastomeric material described herein.

[0067] Figures 3A to 5 illustrate a die for a twin-screw extruder having two sets of slots, each set of slots being aligned with each screw of the extruder. It should be understood, however, that a similar die could be designed for a single-screw extruder having only one set of slots. As illustrated in Figures 3A, 3B and 3C, in one embodiment, a die 330 comprises a fixed die body 331, a first face 330A of the die body 331, an opposite face 330B of the die body 331, and at least one non-circular slot 332 extending through the die body 331 from an inlet, for example 334, which receives the elastomer material extruded by the extruder, at the level of the first face 330A, to an outlet, for example 335, in which the elastomer material is extruded out of an outlet of the extruder, at the level of the opposite face 330B, thus forming a passage.

[0068] Figure 3A illustrates a die 330 comprising two sets of slots 332, each set of slots consisting of a plurality of slots. Each slot can be of any closed shape, for example, circular or non-circular. Figure 3A represents a plurality of non-circular slots, the term "non-circular" denoting shapes that are not circular or that do not have a roundness close to or similar to that of a perfect circle. The shape of the non-circular slot can be asymmetrical or symmetrical and can be any closed shape comprising a mixture of straight and curved lines, or similar shapes. Examples of non-circular shapes include oval or ovular, bean-shaped, trapezoidal, triangular, rectangular, or similar shapes. In some embodiments, the term "Non-circular" refers to elongated shapes, which may be elliptical, oval, or oval-like. The slits 332 are non-circular and have an elongated oval shape or a stadium shape in which two curved ends are connected by parallel straight sides or edges. In other embodiments, two curved ends may be connected by non-parallel straight sides or edges (e.g., petal-like). Although oval, ovular, or elongated oval shapes are described here, this description is not exhaustive. A central axis, which may be a centerline, "CL," along the length of the slit 332, is shown to be parallel to the straight or linear edges. In some embodiments, the centerline is aligned with the longest dimension of the slit opening, as shown in [Fig. 3B].

[0069] In some embodiments, at least a portion of one or more of the edges of the slot 332 may define the cutting edge. In some embodiments, one or more edges (for example, at least the straight edges) of the stage-shaped slot opening 332 function as a cutting surface when the extruder screw rotates and applies a shearing force to the elastomer composition against the slot 332. In some embodiments, the cutting edge may be straight, wavy, or serrated.

[0070] In some embodiments, an inner surface of the slot is conical, that is, tapered. Figures 3B and 3C show the slot 332 as having an inner surface 332A with one or more walls that are conical such that the opening 334 at the first face 330A is smaller than the opening 335 at the opposite face 330B. If the direction of the extruded material passes from the smaller first face 330A, through the inner surface 332A and out through the opposite face 330B, as illustrated in [Fig. 3C], the inner surface of the slot 332 will have an outward taper. It can be appreciated that an inward taper (conical inward) can be obtained with an opening at the opposite face 330B which is smaller than the opening at the first face 330A (not shown).In some embodiments, the area of ​​the smaller opening is between 20% and 90% of the area of ​​the larger opening, for example, between 30% and 80%, or between 30% and 70%, or between 40% and 70% of the area of ​​the larger opening, and between other intermediate ranges.

[0071] In some embodiments, the non-circular slot 332 can be tapered asymmetrically from the opening 334 at the first face 330A to the opening 335 at the opposite face 330B, for example asymmetrically with respect to a central line "CL" from the opening 335 at the opposite face 330B, as illustrated in [Fig. 3B]. In some embodiments In embodiments, asymmetrical taper can be achieved by arranging the respective openings of the slot 332 non-concentrically; for example, the first opening is non-concentric with respect to the second opening. Referring to [Fig. 3B], the opening 334 on the first face 330A is not concentric with the opening 335 on the opposite face 330B. In other embodiments, for example, the openings of the inner slot 332 are concentric and can result in symmetrical taper with respect to a central line "CL" of the non-circular slot 332 (not shown).

[0072] In certain embodiments, whether the taper is symmetrical or asymmetrical, a cross-section of the conical inner surface 332A can define a taper angle, represented by θ in [Fig. 3C]. In certain embodiments, the cross-section can be taken along the centerline CL of an opening. In certain embodiments, the taper angle is between 20° and 60°, for example between 20° and 50° or between 30° and 60° or between 30° and 50°, or other intermediate ranges.

[0073] In certain embodiments, during the rotation of the screw, the material is forced against the edge of the conical surface in which the selected angle of taper and / or the asymmetric taper can maintain the composition on a cutting edge of at least one slot which aligns substantially with a direction of a vector combining the tangential and radial forces imposed on the composition extruded through the die.

[0074] In other embodiments, at least one wall of the inner surface 332A of the slot 332 may be substantially flat, convex, or concave. In other embodiments, at least one wall of the inner surface 332A is convex, or two walls are concave, or one wall is substantially flat and an opposite wall is convex or concave, or one wall may be convex and the opposite wall may be concave. In some embodiments, the inner surface 332A includes at least one wall that is beveled. The beveled wall may be substantially flat, concave, or convex. Figure 3C shows a substantially flat beveled wall of the inner surface 332A opposite a substantially flat, unbeveled wall.

[0075] The slots 332 are shown in [Fig. 3B] as having a radial length 335A relative to a circumferential width 335B defining the opening or hole of the opening 335 at the opposite face 330B and a radial length 334A relative to a circumferential width 334B defining the opening or hole of the opening 334 at the first face 330A. In some embodiments, the radial length 334A, 335A relative to the circumferential width 334A, 335B of the opening 334, 335 can be defined by a ratio between 1.1:1 and 10:1, or between 1.1:1 and 8:1, or between 1.1:1 and 6:1, or between 1.1:1 and 5:1, or between 1.1:1 and 4:1, for example between 1.5:1 and 10:1, and more preferably between 2:1 and 3:1, and intermediate ranges. In some embodiments, the area of ​​the slot 332 (or the total area when there is more than one slot) may be between 200 mm² and 3,000 mm², and preferably between 300 mm² and 2,500 mm².

[0076] In certain embodiments, to optimize cutting performance, each slot opening is positioned in a region of the die corresponding to the screw as defined by the outside diameter of a screw thread. Figure 3A illustrates a circular region in the die 330 corresponding to the outside diameter OD of a corresponding screw thread 324 / OD. The respective openings of each slot 332 are positioned so as not to extend beyond the outside diameter of the screw thread 324 / OD. Furthermore, the openings of each slot 332 do not extend substantially into a circular region of the die 330 corresponding to the outside diameter of a corresponding screw shaft 320 / OD. In some embodiments, no more than 20% or no more than 10% of the slot opening 332 extends into the circular region of the die 330 corresponding to the outside diameter of a corresponding screw shaft 320 / OD.By positioning the slot openings substantially between the outside diameter of the 320 / OD screw shaft and the outside diameter of the 324 / OD screw thread, without wishing to limit ourselves to theory, it is understood that such a die design can minimize a change in the flow direction of the elastomer material product when it leaves the screw thread and flows through the slots or holes in the die, which can maintain good contact between the elastomer material and the cutting surface to result in the cutting of the product into discrete pieces having the sizes and shapes described herein.

[0077] In some embodiments, the at least one non-circular slot 332 comprises a plurality of non-circular slots 332. With reference to the left side of [Fig. 3A], the plurality of slots 332 may be distributed equidistant from each other in the regions described herein (essentially between the outside diameter of the screw shaft 320 / OD and the outside diameter of the screw thread 324 / OD). In some embodiments, each of the plurality of slots is also provided equidistant from a midline or center portion or midpoint. Figure 3A illustrates an arrangement of a plurality of slots 332 equidistant from each other, in which the outer edges of the slots establish a circular contour 340. The plurality of slots 332 can be arranged concentrically with respect to the outer diameter of the screw thread 324 / OD, in which the openings of the slots 332 do not extend beyond the outer diameter 324 / OD.The plurality of slits 332 is also arranged equidistant with respect to a median part or . central 336 or at a midpoint SA. However, the arrangement is not limited to a circular shape and can form other shapes (oval, square, rectangular, etc.) as long as the central or midpoint 336 or the midpoint SA of the plurality of slots is substantially aligned coaxially with the corresponding screw provided in the extruder. For a twin-screw extruder, two sets of a plurality of non-circular slots are provided. In some embodiments, each set of the plurality of non-circular slots is substantially aligned coaxially with the corresponding screw provided in the extruder.

[0078] In some embodiments, each slot 332 is substantially aligned with the direction of the vector combining the tangential and radial forces imposed on the material extruded through the die 330 by the extruder. As previously disclosed, this alignment can be achieved by means of certain conical designs of the inner surface of the slot 332. In other embodiments, this sensible alignment can be achieved by means of the positioning of the slots. In some embodiments, the plurality of slots is positioned in a circular shape and equidistant from each other and equidistant from a mid or central portion 336, or a midpoint SA, which is coaxially aligned with the corresponding screw. A center line or a central axis of the slot (for example, coinciding with the longest dimension of the slot) can be offset with respect to an axial axis of the extruder screw. This is illustrated in [Fig.[Fig. 3A] illustrating the centerline CL of slot 332, which is aligned with the longest dimension of slot 332. It can be seen that the centerline CL is offset from a radius that aligns with an axial axis SA of the extruder screw. Fig. 3A designates angle [3] as the angle from which the centerline CL of slot 332 is offset from the axial axis SA. Angle [3] can be between 20° and 50°, for example between 20° and 45°, or 20° and 40°, or 25° and 50°, or 25° and 45°, or 25° and 40°, or 30° and 50°, or 30° and 45°, or 30° and 40°. Thus, each set of the plurality of non-circular slots 332 can be offset radially with respect to an axial axis of the extruder screw.

[0079] Two sets of the plurality of non-circular slots 332 can be provided for a twin-screw extruder. In some embodiments, the sets of the plurality of non-circular slots 332 overlap due to the meshing of the screw threads. In the embodiment illustrated in [Fig. 3A], the die 330 has 8 slots per set, but this description is not intended to be limiting. Rather, it is understood that the die 330 can include any number of slots, for example from 1 to 100 slots, and preferably between 2 and 100 slots, and more preferably between 4 and 40 slots, depending on the size of the extruder, for example TSR 125 or TSR 330, and / or the available space on the end plate. and / or to maximize the open area of ​​the die. For example, in some embodiments, the end plate 330 may have a total area defined by the length and width of the opposite face of the die body, and the plurality of non-circular slots 332 defines an opening of between 20% and 60% of the total area of ​​the die face; for example, the holes or openings forming the passage on the opposite face occupy between 20% and 60% of the area of ​​the opposite face. In some embodiments, in which the twin screws are not parallel to each other, the die 330 may include an angle or bend between the sets of the plurality of non-circular slots, so that the die 330 can align with the end of the screw or screws of the extruder.

[0080] Figures 4A and 4B illustrate another embodiment of a die 430 comprising a fixed die body 431, a first face of the die body, an opposite face 430B of the die body, and at least one bean-shaped slot 432 extending through the die body 431 from an inlet 434, for example, which receives the elastomer material extruded by the extruder, at the level of the first face, to an outlet 435, in which the elastomer material is extruded towards an outlet of the extruder, at the level of the opposite face 430B, thus forming a passage.

[0081] As shown in [Fig. 4B], which is a schematic illustration of an assembly of a plurality of slots with respect to a screw, in some embodiments the plurality of bean-shaped slots 432 can be provided in a circular shape, for example, the slots are provided concentrically around a median or central part, or a midpoint, of the plurality of bean-shaped slots 432, in which a median or central part of the bean-shaped slots 432 can be concentric with the shaft of the screw 420. Thus, the bean-shaped slots 432 can be provided on the die 432 which is concentric and corresponds to an outside diameter of the screw thread, for example, a perimeter of the first opening 434 is concentric with the outside diameter of the screw thread.In some embodiments, the bean-shaped slots 432 may be provided at equidistant intervals from the adjacent bean-shaped slot, for example at increments of 120° for three bean-shaped slots.

[0082] Figure 5 illustrates another embodiment of a die 530 which includes a fixed die body 531, a first face of the die body, an opposite face 530B of the die body and at least one slot 532 which extends through the die body 531. The slot 532 has an inner surface which is conical such that a first opening at the level of one of the first face or the opposite face 530B is smaller than a second opening at the level of the other of the first face or the opposite face 530B, including the at least one slot 532 (conicity not shown).

[0083] In some embodiments, the inner surface is conical through the die body 431, 531 such that the first opening, for example, intended to receive the extruded elastomer material, is smaller than the second opening, for example, intended to extrude the elastomer material from the extruder. In some embodiments, the slot 432, 532 is conical forward from the first face to the opposite face such that the first opening at the first face is smaller than the second opening at the opposite face. In some embodiments, the inner surface of the slot 432, 532 is conical in the opposite direction from the first face to the opposite face such that the second opening at the opposite face is smaller than the first opening at the first face.The taper, or tapering, of the inner surface of at least one slot 432, 532 is configured to hold the material on a cutting edge, for example, a portion of the slot 432, 532 in contact with the extruded elastomer material. In some embodiments, the die 530 may be rotary, in which the cutting edge is an associated blade.

[0084] The slot 532 can be formed in various geometric shapes depending on a number of different factors, including, but not limited to, the extruded material, the taper direction of the inner surface, the desired shape and / or size of the extrudate, or the like. In some embodiments, the slot 532 has a trapezoidal shape having at least one linear edge, for example at least a portion of the cutting edge, defining at least a portion of the first opening that is substantially aligned with the direction of the vector combining the tangential and radial forces imposed on the extruded material through the die 530 by the extruder.In some embodiments, the slot 532 extends in a radial direction, such that a first end 532B of the slot 532, which is closer to the center of a plurality of slots, has a width (in a circumferential direction) less than the width of a second end 532C of the slot 532 that is opposite the first end, for example, the one closest to the diameter of the screw thread 524; for example, the width of the second end 532C is wider than the width of the first end 532B (in a radial direction). In some embodiments, at least one linear edge includes wavy or serrated edges that form at least a portion of the linear edge.

[0085] In some embodiments, the at least one non-circular slot 532 comprises a plurality of non-circular slots 532. With reference to the left side of [Fig. 5], the slots may be arranged concentrically from a central or median portion 536, for example, between the outside diameter of the shaft screw 520 and the diameter of the screw thread 524. In some embodiments, each of the plurality of slots is arranged equidistant from the central or median portion 536. For a twin-screw extruder, two sets of a plurality of non-circular slots are provided. In some embodiments, each set of the plurality of non-circular slots is aligned substantially coaxially with the corresponding screw provided in the extruder.

[0086] In certain embodiments, as illustrated in Figures 6A to 7C below, the screw or screws may be specially designed to engage and / or align with the die 130, 230, 330, 430, 530. For example, in certain embodiments, the screw or screws may be configured so that at the second output end of the shaft, the shaft and at least one helical screw thread together form an end portion having a flat face, for example to process the elastomer material through the die.

[0087] As illustrated in Figures 6A, 6B and 6C, at least one screw 620 is specifically designed to engage and / or align with the die 130, 230, 330, 430, 530. The screw 620 can be configured so that at the second output end 622B of the shaft 622, the shaft 622 and at least one helical screw thread 624 together form an end portion 626 having a flat face, for example for processing the elastomer material through the die. The screw 620 is configured, designed or otherwise provided so that, when the screw 620 rotates, for example counterclockwise, the end portion 626 imposes tangential forces "TAN" and radial forces "RAD" on the elastomer material, so that the elastomer material is forced into or extruded through the die slot(s) in a vector direction "V".Although only one vector, which is the combination of tangential and radial forces, is represented in the figures, it should be noted that the elastomeric material is forced or extruded in a respective vector direction at each slot along the die, for example in a different vector direction at each slot or each of the slots.

[0088] In some embodiments, the end portion 626 may have an area between 20% and 70% of an area defined by an outside diameter of at least one helical screw thread 624, and in some embodiments, between 20% and 60%, or between 20% and 50%, or between 20% and 40%, or between 20% and 30%, or between 25% and 70%, or between 25% and 60%, or between 25% and 50%, or between 25% and 40%, or between 25% and 35%, or between 30% and 70%, or between 30% and 60%, or between 30% and 50%, or between 40% and 50% of the area defined by the outside diameter of at least one helical screw thread, for example the helical screw thread 624. In certain embodiments, the outside diameter of at least one helical screw thread 624 may be the area defined by the maximum outside diameter of at least one helical screw thread 624, for example the diameter of the largest large thread, or the outside diameter of at least one helical screw thread at the second output end 622B, for example the diameter of the smallest thread.

[0089] In other words, in certain embodiments, the end portion 626 of the screw 620 is modified for use with the die 130, 230, 330, 430, 530. In certain embodiments, the screw 620 can be shortened to form the end portion 626 with the flat face by truncating the end of the screw 620 to obtain a specific length, for example, to form the end portion having the flat face intended to engage and / or align with the die 130, 230, 330, 430, 530. Thus, the end portion 626 of the screw 620 has a clearance distance between the end portion 626 and the die 130, 230, 330, 430, 530 of between 0.5 mm and 5.0 mm, for example between 0.5 mm and 3.0 mm or between 0.5 mm and 2.0 mm, preferably between 0.8 mm and 2.0 mm, and more preferably between 1.0 mm and 2.0 mm or between 1.5 mm and 2.0 mm, and the intermediate ranges.

[0090] As illustrated in [Fig.6B], in some embodiments, the thickness "T" of the end part having the flat face (or the wedge-shaped part 628) is between 5 mm and 15 mm, preferably between 7.5 mm and 15 mm, and more preferably between 7.5 mm and 10 mm, while the thickness "TF" of the screw thread can be between 10 mm and 20 mm.

[0091] As illustrated in more detail in [Fig. 6C], in some embodiments, the flat face of the end portion 626 comprises a circular portion 627 and a wedge-shaped portion 628. The wedge-shaped portion 628 is at least partially formed by a portion of at least one helical screw thread 624, such that the wedge-shaped portion 628 is configured to align with at least one non-circular slot of the die 130, 230, 330, 430, 530. In some embodiments, the wedge-shaped portion 628 may comprise an outer edge 628B formed by at least one helical screw thread, such that the outer edge 628B and the wedge-shaped portion define a sector having an angle α between 20° and 100°, and preferably between 20° and 50°.In some embodiments, the length "L" of the wedge-shaped portion 628 relative to the screw axis "SA" of the circular portion 627 is at least 70% of the radius formed by the widest length of at least one helical screw thread 624, for example the radius of the largest thread of the helical screw thread 624. In some embodiments, the end portion 626 of the shaft 622 and the helical screw thread 624 can be provided by truncating the end of the screw 620.

[0092] In some embodiments, the wedge-shaped portion 628 of the flat face of the screw 620 can be configured such that the wedge-shaped portion 628 has an area between 0.9 and 3 times, or between 0.9 and 2 times, and preferably between 0.9 and 1.5 times, the area of ​​at least one non-circular slot of the die 130, 230, 330, 430, 530. Thus, at least a portion of the flat face, such as the wedge-shaped part 628, is configured to align with at least one non-circular slot of the die so that the part of the flat face covers or overlaps the entirety of at least one non-circular slot of the die at each rotation of the screw 620, which, surprisingly, has been found to contribute to the cutting of the elastomer material, so that the extruded elastomer material has a length not exceeding 500 mm, and preferably between 50 mm and 150 mm.

[0093] Figures 7A, 7B, and 7C illustrate another embodiment of an end portion of at least one screw 720, which can be used in any of the extruder embodiments, for example 100 or 200, as described herein, and which may have identical or similar characteristics to those of the screw 620 described above. As illustrated in [Fig. 7B], in some embodiments, the flat face of the end portion 726 comprises a circular portion 727 and a wedge-shaped portion 728 that is narrower than in the embodiments of Figures 6A, 6B, and 6C. As shown in [Fig. 7C], the wedge-shaped portion 728 covers or overlaps at least 90% of the opening surface of the non-circular slot 732.In some embodiments, the wedge-shaped part 728 of the flat face of the screw 720 can be configured so that the wedge-shaped part 728 has an area between 0.9 and 1.5 times the area of ​​the non-circular slot 732 of the die 730.

[0094] Although the screw 620, 720 has been described above with reference to a single screw, this disclosure is not intended to be limiting. Rather, it is understood that at least one screw 620, 720 may be used in a twin-screw extruder, in which the paired screws taper towards each other. The twin-screw extruder may be configured so that the screws 620, 720 are provided as counter-mesh screws inside the housing, tapering towards each other. Fig. 7A shows screw 720, which is part of the twin screws, applying tangential (“TAN”) and radial (“RAD”) forces to the elastomer material in order to make the elastomer material flow in a vector direction (“V”) which is a combination of the tangential and radial forces, out of the die 130, 230, 330, 430, 530.In some embodiments, a minimum clearance C between the second exit ends of the twin screws 620, 720, for example the part of the helical screw threads 624, 724 which mesh to force or extrude the elastomer material through the die, for example 130, 230, 330, 430, 530, is between 10 mm and 25 mm, preferably between 15 mm and 22 mm.

[0095] Thus, the extruder, for example 100 or 200, is configured to extrude elastomeric compositions. In some embodiments, the extruder is configured to have a screw rotation speed between 5 rpm and 50 rpm, and preferably between 10 rpm and 35 rpm. In some embodiments, the extruder is configured to maintain one or more of the The following elements: a temperature of a main body, for example a chamber, of the extruder housing the screws, between 55 °C and 90 °C; a temperature at the center of the end plate between 100 °C and 150 °C; or a temperature of the elastomer material between 100 °C and 140 °C. Thus, the extruder is configured to provide an elastomer material exit speed between 0.05 m / min and 30 m / min, for example, between 0.1 m / min and 30 m / min, and preferably between 0.05 m / min and 16 m / min, and more preferably between 0.1 m / min and 16 m / min.

[0096] In some embodiments, the extruder is configured to extrude an elastomeric material (extrudate) cut into discrete pieces. In some embodiments, the extrudate has a length not exceeding 500 mm. The term "length" here refers to the longest dimension of an extrudate that can be formed with a straight line, while the width is the longest dimension perpendicular to the length. In some embodiments, the extrudate has a length not exceeding 500 mm, for example not exceeding 400 mm, or not exceeding 300 mm, or not exceeding 250 mm, or not exceeding approximately 200 mm, or not exceeding approximately 150 mm, for example between 20 mm and 500 mm, between 20 mm and 400 mm, between 20 mm and 300 mm, between 20 mm and 250 mm, between 20 mm and 200 mm, or between 20 mm and 150 mm. Other intermediate ranges are also envisaged.

[0097] In certain embodiments, the extrudate has an aspect ratio between length and width of between 1.5:1 and 5:1, for example, between 1.5:1 and 4:1, or between 1.5:1 and 3:1, or between 1.5:1 and 2:1, or between 2:1 and 5:1, or between 2.5:1 and 5:1, or between 3:1 and 5:1. With such aspect ratios, the extrudate can have a width of between 20 mm and 300 mm, for example between 20 mm and 200 mm, between 20 mm and 150 mm, between 20 mm and 100 mm, or between 20 mm and 75 mm, or between 20 mm and 50 mm.

[0098] In some embodiments, the extrudate has a thickness between 2 mm and 25 mm, for example a thickness between 3 mm and 25 mm, or between 5 mm and 25 mm, or between 7 mm and 25 mm, or between 10 mm and 25 mm, or between 2 mm and 20 mm, or between 3 mm and 20 mm, or between 5 mm and 20 mm, or between 7 mm and 20 mm, or between 10 mm and 20 mm, or between 2 mm and 15 mm, or between 3 mm and 15 mm, or between 5 mm and 15 mm, or between 7 mm and 15 mm, or between 10 mm and 15 mm, or between 2 mm and 10 mm, or between 3 mm and 10 mm, or between 5 mm and 10 mm.

[0099] In some embodiments, the extruder is configured to provide an extrudate having a surface area between 0.0005 and 0.01 m2, for example between 0.0005 and 0.007 m2.

[0100] In some embodiments, the extruder is configured to extrude an elastomeric material into discrete pieces in which the extrudate has a curved shape. In some embodiments, the extrudate has a curvature angle (degree of curvature) in at least one dimension between 50° and 160°, or between 50° and 150°, or between 60° and 160°, or between 60° and 150°, or between 70° and 160°, or between 70° and 150°. In other embodiments, the extrudate has a curvature angle in two dimensions between 50° and 160° or other ranges described herein. The angle of curvature can be determined from a portion of the main body of the extrudate, for example, the portion of the extrudate having a thickness of at least 2 mm, or at least 3 mm, or at least 5 mm, or at least 7 mm, or at least 10 mm, up to 25 mm or up to 20 mm. The main body portion would not include the thin flakes of material formed, for example, at the periphery of the extrudate.The main body portion could be the entire extrudate or could define a perimeter within a surface of the extrudate having a minimum thickness of at least 2 mm, or other dimensions described herein. Thus, in some embodiments, the extrudate comprises a main body portion having a curvature angle in at least one dimension between 50° and 160°.

[0101] In some embodiments, the angle of curvature can be defined as a central angle of a perimeter defining the principal body part in which the angle of curvature in at least one dimension is between 50° and 160°. For example, the angle of curvature can be determined using imaging software, such as ImageJ, available at https: / / imagej.net / . As shown in [Fig. 8A], the contour of the extrudate can be fitted to an ellipse from which the x and y axes (major and minor axes) can be determined by the software. The x-axis is aligned along the longest straight-line dimension of the extrudate (the "length" of the extrudate, as defined earlier here), while the y-axis is aligned with the width of the ellipse. As shown in [Fig. 8A], "a" denotes half the width and "b" denotes half the length.The angle of curvature, a, can be determined from the equation: a = 180° - 2[3 where B = arctan(a / b)*180 / ir. .

[0102] In some embodiments, the angle of curvature may be two-dimensional and may give rise to various geometric shapes, such as a spoon. For example, the extrudate may have a substantially flat main body portion with another main body portion having an angle of curvature in at least one dimension between 50° and 160° (e.g., curves, twists, or the like), so that the elastomeric extrudate as a whole is not flat in any dimension. It is understood that the term "substantially flat" refers to the main body portion that is considered non-curved, i.e., having an angle of curvature less than 50°.

[0103] In some embodiments, the extrudate has a length not exceeding 500 mm, or other ranges described herein, for example a length between 20 mm and 150 mm, and (a main body part having) a curvature angle, in at least one dimension, between 50° and 160°, or other ranges described herein, and / or a length-to-width aspect ratio between 1.5:1 and 5:1, or other ranges described herein, and / or a thickness between 2 mm and 25 mm, or other ranges described herein. Other characteristics described in this document are also considered.

[0104] In certain embodiments, the elastomeric extrudate having (a main body portion with) a curved shape in at least one dimension may have an irregular shape, for example, a shape that is not a pellet, cylindrical, flat sheet, or similar. Without being limited to theory, the shape of the elastomeric extrudate may be due to the fact that the elastomeric material is subjected to more deformation at its periphery than at its center, for example, partly because of the configuration of the screw and / or die, so that the regions of high deformation are subjected to a degree of permanent "stress" because the rubber chain is less entangled.

[0105] Figures 8B to 8D show illustrative embodiments of an extrudate 860, for example, an elastomeric material extruded from a screw extruder as described herein. In some embodiments, the elastomeric material is formed by extruding it through a single-screw or twin-screw extruder, as described above. In some embodiments, the elastomeric material is specially processed using an extruder having one or more of the following features:

[0106] As illustrated in [Fig. 8B], in one embodiment of the elastomeric extrudate 860, the elastomeric extrudate 860 has an irregular shape, for example, a shape that is not a pellet, cylinder, flat sheet, or the like, in which a principal body portion has a curvature angle θ, in at least two dimensions, of between 50° and 160°. The principal body portion 862 further comprises a length, a width, and a thickness. Thus, the elastomeric extrudate 860 has a "spoon" shape, in which the principal body portion 860 has a curvature angle in at least the length and width directions.

[0107] In some embodiments, the length of the main body part 862 is not greater than 500 mm and, preferably, is between 20 and 150 mm, and more preferably between 50 and 150 mm. In some embodiments, the length and / or width is not less than 20 mm. In some embodiments, the main body part 862 may have an aspect ratio between the length and width of the main body part of between 1.5:1 and 5:1. Thus, the main body part 862 may have an area of ​​between 0.0005 and 0.01 m², and preferably between 0.0005 and 0.007 m². In some In some embodiments, the main body part 862 has a thickness "TS" of between 2 mm and 25 mm, for example between 2 mm and 20 mm, and preferably a thickness of between 2 mm and 20 mm. In some embodiments, the thickness of the main body part 862 is uniform or substantially uniform; for example, it has the same or substantially the same thickness throughout the main body part 862.

[0108] Figures 8C and 8D illustrate an embodiment of the elastomeric extrudate 960 in which the elastomeric extrudate 960 has a main body portion 962 having a length L and a width W and a curvature angle θ, in at least two dimensions, between 50° and 160°. These parameters can be provided by the extrusion process (and / or depending on the properties of the elastomeric material being extruded). In some embodiments, the curvature angle θ can be defined as a central angle of the main body portion delimiting a perimeter of the main body portion 962 in which the curvature angle, in at least two dimensions, is between 50° and 160°. The elastomeric extrudate 960 is represented as having a "spoon" shape, in which the main body part 960 has an angle of curvature in at least the length or width directions and is not planar in the usual sense of the term.Figures 8C and 8D represent an extrudate in which the main body part 962 is equivalent to the entire extrudate. In other embodiments, an extrudate may have, at the edge, parts of a minimum thickness, for example less than 2 mm or less than 3 mm or less than 5 mm, which would not be considered as a main body part.

[0109] In some embodiments, the main body part 962 includes a twisted portion. In some embodiments, the main body part 962 may include at least one curved portion on at least one part of the main body part 962. The at least one curved portion and / or the at least one twisted portion may have an angle of curvature in at least one dimension, for example along the length and / or width, of between 50° and 160°. In some embodiments, the length and / or width of the main body part 962 are as described for the extrudate 862.

[0110] This disclosure also relates to a plurality of extrudates. In some embodiments, the plurality of extrudates has a uniform or substantially uniform size distribution, for example, at least 75% of a plurality of extrudates have a length not exceeding 500 mm (or other ranges described here, for example, a length between 20 mm and 150 mm), and at least 75% of the plurality of extrudates have (a principal body part having) an angle of curvature, in at least one dimension, between 50° and 160°. Optionally, at least 75% of the plurality of extrudates have an aspect ratio between length and width of between 1.5:1 and 5:1, or other ranges described here, and / or a thickness of between 2 mm and 25 mm, or other ranges described here.

[0111] In other embodiments, at least 80% of the plurality of extrudates have a length not exceeding 500 mm, for example, at least 85%, or at least 90%, or at least 95% of the plurality of extrudates have a length not exceeding 500 mm, or other ranges described here, for example, a length between 20 mm and 150 mm. In other embodiments, between 75% and 100%, or between 75% and 99%, or between 80% and 100%, or between 80% and 99%, or between 85% and 100%, or between 85% and 99%, or between 90% and 100%, or between 90% and 99%, or between 95% and 100%, or between 95% and 99% of the plurality of extrudates have a length not exceeding 500 mm, or other ranges described herein, for example a length between 20 mm and 150 mm.

[0112] In certain embodiments, at least 75% of a plurality of extrudates have a thickness between 2 mm and 25 mm, for example, a thickness between 3 mm and 25 mm, or between 5 mm and 25 mm, or between 7 mm and 25 mm, or between 10 mm and 25 mm, or between 2 mm and 20 mm, or between 3 mm and 20 mm, or between 5 mm and 20 mm, or between 7 mm and 20 mm, or between 10 mm and 20 mm, and / or an aspect ratio between length and width between 1.5:1 and 5:1, for example, between 1.5:1 and 4:1, or between 1.5:1 and 3:1, or between 1.5:1 and 2:1, or between 2:1 and 5:1, or between 2.5:1 and 5:1, or between 3:1 and 5:1.In other embodiments, at least 80% of the plurality of extrudates have the thicknesses and / or aspect ratios described herein, such as a thickness between 2 mm and 25 mm and / or an aspect ratio between length and width between 1.5:1 and 5:1, for example, at least 85%, or at least 90%, or at least 95% of the plurality of extrudates have a thickness between 2 mm and 25 mm, and / or an aspect ratio between length and width between 1.5:1 and 5:1, or other ranges described herein. In other embodiments, between 75% and 100%, or between 75% and 99%, or between 80% and 100%, or between 80% and 99%, or between 85% and 100%, or between 85% and 99%, or between 90% and 100%, or between 90% and 99%, or between 95% and 100%, or between 95% and 99% of the plurality of extrudates have a thickness between 2 mm and 25 mm and / or an aspect ratio between length and width between 1.5:1 and 5:1, or other ranges described herein..

[0113] In some embodiments, at least 80% of a plurality of extrudates have a curvature angle in at least one dimension between 50° and 160°, for example, at least 85%, or at least 90%, or at least 95% of the plurality of extrudates have a curvature angle in at least one dimension between 50° and 160°. In still other embodiments, between 75% and 100%, or between 75% % and 99%, or between 80% and 100%, or between 80% and 99%, or between 85% and 100%, or between 85% and 99%, or between 90% and 100%, or between 90% and 99%, or between 95% and 100%, or between 95% and 99% of the plurality of extrudates have an angle of curvature, in at least one dimension, between 50° and 160°.

[0114] In one aspect, the extrudate or plurality of extrudates can be useful in bale formation. It is common to supply rubber masterbatches in the form of solid bales. If the solid form is used for blending or compounding, the high density and / or strength of the material will generally result in long processing times. The bale size could be reduced before blending (e.g., using a bale granulator), but this would require adapting the equipment to an existing blending line. Furthermore, compacting the granulated pieces can still produce an agglomerate with a high density, which offers only a minimal advantage over the solid form. Alternatively, the masterbatch could be supplied in sheet form.However, depending on the product, the additional energy required to convert the product into a usable sheet form can negatively impact the final product performance. Furthermore, such a sheet (or granulated form) typically requires a non-stick coating, which is undesirable in some applications.

[0115] Attempts have already been made to manufacture a more processable rubber masterbatch ball. For example, a "loose ball" can be created by first forming the masterbatch into small pieces and then compressing the pieces together in a rubber baler. The masterbatch pieces can be formed by converting the product into a narrow strip, 40 to 60 mm wide, before cutting it into strips at high speed. Alternatively, the masterbatch can be processed in a single-screw extruder equipped with a pelletizing head. These processes generally produce pieces with a shortest dimension not exceeding 10 mm. Such processes generally produce balls containing up to 20% void volume, although balls containing up to 40% void volume have been described (see U.S. Patent No. 7,341,142).Depending on the effective viscosity of the masterbatch, mixing these bales may still result in a prolonged processing time if they are processed whole, even if the individual pieces have been coated with a non-stick agent before baling.

[0116] Because the extrudates have an angle of curvature, as described herein, a ball containing such extrudates will not be as easily and efficiently compacted as a ball containing regularly shaped extrudates. In some embodiments, a ball containing the extrudates may have a void volume of between 50% and 90%, or a void volume fraction of at least 0.5% or less. between 0.5 and 0.9. This is due, at least in part, to the fact that the extrudate has a curvature angle in at least one dimension, and preferably in at least two dimensions. This increased void volume or void fraction can facilitate rapid compounding, as the extrudates in the bale can be conveyed directly to mixing, compounding, or roller milling equipment without further processing, compared to a bale with a lower void volume or void fraction—for example, a bale that is more compacted and more efficiently.

[0117] The term "void volume" refers to the percentage of void volume, i.e., air gaps, spaces, or interstices, in a bale or in the occupied portion of a container of elastomeric composite pieces or extrudates. When the elastomeric composite pieces are baled, the void volume can be determined by subtracting the volume of the elastomeric composite pieces (which can be calculated from the total weight of the pieces and the material density, as weight per unit volume) from the total volume of the bale. The void fraction is obtained by dividing the total volume of the bale; the void volume is obtained by multiplying the void fraction by 100.

[0118] The shape of the extrudates prevents compaction of the extrudates within a ball, which facilitates rapid cooling. This shape is optimal for feeding downstream equipment, such as Banbury mixers or roller mills. The ball can be quickly ingested by a mixer or roller mill due to its low density; for a void volume fraction of 0.5, the density is no more than 0.5 g / cm³ or 0.6 cm³.

[0119] Figure 9 represents a ball 970 of elastomeric extrudates 1060, which may have the same or similar characteristics to the extrudates 860, 960 described above, and which may be combined for further processing, for example by downstream customers, to form the final product. In some embodiments, the elastomeric extrudate(s) 1060 may comprise a plurality of elastomeric extrudates which may be combined in various forms, including, but not limited to, an agglomerate of pieces, such as a ball, in a bag, or similar. In some embodiments, the elastomeric extrudate can have a product density between 800 kg / m3 and 1,500 kg / m3. In some embodiments, the plurality of elastomeric extrudates 1060 can be formed into a ball 970.In some embodiments, the 970 ball may have a substantially rectangular shape, but this disclosure is not intended to be limiting. The shape of the 970 ball may instead be cylindrical, parallelepiped, or similar. In some embodiments, the 970 ball may have any shape. A dimension known in the art. For example, the 970 ball can have a width between 10 and 15 inches, and / or a length between 25 and 30 inches, and / or a depth between 3 and 10 inches. Other dimensions are readily apparent to a person skilled in the art.

[0120] In some embodiments, the ball 970 is formed of a plurality of elastomeric extrudates 1060 in which at least 75% of the plurality of elastomeric extrudates have a length not exceeding 500 mm, and at least 75% of the plurality of elastomeric extrudates have (a part of the main body having) an angle of curvature in at least one dimension between 50° and 160°, and other dimensions and ranges described herein.

[0121] In some embodiments, the extrudate can be formed by processing a composition using an extruder having a die plate with at least one non-circular slot extending through a die body of the fixed die from a first face of the die body to an opposite face of the die body which opposes the first face, thus forming a passage, so that the composition is forced through an inner surface of the at least one non-circular slot, in which the inner surface is conical such that a first opening at one of the first face or the opposite face is smaller than a second opening at the other of the first face or the opposite face.In some embodiments, at least one slot is configured to align substantially with the direction of a vector combining tangential and radial forces on the composition extruded through the die from the extruder.

[0122] In some embodiments, the ball can be produced by filling a ball-shaped bag with a plurality of elastomeric extrudates as described herein. In some embodiments, the bag is placed in a container whose shape is such that the ball will take the shape of the container. In some embodiments, the ball is a "loose ball" in which minimal or no pressure is applied by a plunger or similar device for the purpose of adjusting the plurality of extrudates in the container.

[0123] The elastomeric composition, whether a composite or a vulcanizate, resulting from the extrusion comprises at least one elastomer and at least one filler having a content of at least 20 phr. Composites can be considered as an uncured mixture of filler(s) and elastomer(s), optionally with one or more additives, and can be considered as a blend or a masterbatch. The composite can be considered as an intermediate product that can be used in subsequent rubber compounding processes and in one or more vulcanization processes to form cured compounds or vulcanizates.

[0124] 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 may be chosen from at least one of natural rubber, styrene-butadiene rubber and polybutadiene rubber, including mixtures thereof.

[0125] 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. 9,868,853, 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.

[0126] 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.

[0127] 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.

[0128] If two or more elastomers are used, the two or more elastomers may be loaded into the mixer as a mixture all at once (in a single (one or two or more loads) or the elastomers can be added separately in any order and in any quantity. For example, the elastomer may consist of natural rubber mixed with one or more of the elastomers described here, such as 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.

[0129] 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 styrene-butadiene rubber, functionalized styrene-butadiene rubber, and polybutadiene rubber, and / or any other elastomer described herein.

[0130] Natural rubber can also be chemically modified in some way. 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.

[0131] 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 each other. CNS fillers are, described in U.S. Patent RI 9,447,259 and PCT Application RI PCT / US2021 / 027814, the descriptions of which are incorporated herein by reference. Mixtures may also be used, for example, 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 (for example, 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 (for example, silicon-coated materials, silica-coated materials, carbon-coated materials). The filler may be oxidized and / or undergo other surface treatments.There are no limitations on the type of filler (e.g., silica, carbon black, or other filler) that can be used.

[0132] 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.

[0133] 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).

[0134] 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 carbon hydrothermal carbonization (HTC, where the filler comprises lignin that has been treated by hydrothermal carbonization as described in U.S. Patent Nos. 10,035,957 and 10,428,218, 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, polysaccharides may be selected from: poly alpha-1,3-glucan; poly alpha-1,3-1,6-glucan; a water-insoluble alpha-(1,3-glucan) polymer having 90% or more α,3-glycosidic linkages, less than 1% by weight of α-1,3,6-glycosidic branch points and a number-average degree of polymerization between 55 and 10,000; dextran; a composition comprising a poly alpha-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 type II cellulose crystal structure.

[0135] 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.

[0136] 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.

[0137] 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 for applications in various implementations.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.

[0138] 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 are... Examples include 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 non-HDS silica 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, such as Coupsil® 6109 silica.

[0139] 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 as 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, the description of which is incorporated herein by reference.

[0140] 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 may 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 30 ... The percentages can range from approximately 0.5% to approximately 20%, from approximately 0.1% to approximately 15%, from approximately 0.1% to approximately 10%, from approximately 0.1% to approximately 5%, or from approximately 0.1% to approximately 2% by weight, depending on the weight of the silicon-treated carbon black. These amounts can be between approximately 0.5% and approximately 25% by weight, between approximately 1% and approximately 15% by weight of silicon, between approximately 2% and approximately 10% by weight, between approximately 3% and approximately 8% by weight, between approximately 4% and approximately 5%, or approximately 6% by weight, all of these amounts being dependent on the weight of the silicon-treated carbon black.

[0141] In any embodiment and at any stage, a bonding agent may be introduced in any one of the stages (or in several stages or locations) as long as the bonding agent has the possibility of dispersing in the composite. The bonding agent may be or comprise 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 anchoring 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. 6,084,015, 6,194,509, 8,584,725 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. 10,239,971, 10,202,471, 10,787,471 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 elastomer composite, for example in a compounder.

[0142] 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.

[0143] The total charge rate (single charge or mixture of charges) may 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.

[0144] 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 carbon black-coated and treated materials. 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.

[0145] In certain embodiments, 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 elastomeric composite formed may 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.

[0146] 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.

[0147] In some embodiments, the extruder is configured to extrude elastomers that are difficult to process with existing or conventional equipment, for example, twin-screw rollers (TSRs) and fixed-knife device designs. For example, some elastomeric compositions may be difficult to cut into discrete pieces. In some embodiments, the elastomeric compositions may have a dynamic storage modulus of at least 900 kPa, measured at a strain amplitude of 0.3%, G'(0.3%), for example, a dynamic storage modulus of at least 1,000 kPa, for example, between 900 kPa and 3,000 kPa or between 1,000 kPa and 3,000 kPa or between 900 kPa and 2,500 kPa or between 1,000 kPa and 2,500 kPa, at a frequency of 1 Hz and at 100 °C.The dynamic storage module can be measured using equipment known to determine rheological properties, for example a rubber process analyzer (RPA; D-RPA 3000, from MonTech Rubber Testing Solutions) at a strain of 0.3% under conditions of 100 °C at a shear frequency of 1 Hz after a 5-minute static conditioning period, 10 shear cycles at 50% strain and a 30-minute recovery time at 0.3% strain.

[0148] In some embodiments, the elastomeric extrudate is substantially free of rubber chemicals. Most elastomeric compositions are prepared by dry mixing of elastomer and filler in the presence of rubber chemicals. In conventional dry mixing processes, one or more rubber chemicals (e.g., processing aids) are added at the beginning of the mixing cycle to facilitate filler incorporation. Rubber chemicals can be essential, but they can interfere with the bonding or interaction between the filler and elastomer surfaces and negatively impact the properties of the vulcanizate. It has been discovered that mixing a solid elastomer with a wet filler allows mixing in the absence or substantial absence of these rubber chemicals.Without wanting to adhere to any particular theory, it is thought that the presence of a wet charge eliminates the need for rubber chemicals at the beginning of the mixing cycle, or at any time during the mixing cycle, because the liquid comes from. Wet filler allows for longer mixing times, thus improving the incorporation of the filler into the solid rubber without the potential interference of rubber chemicals.

[0149] 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. Mixing with a wet filler introduces liquid into the mixture, thereby enabling control of batch processing time and temperature beyond what is possible with known dry mixing processes. Control of batch processing time optimizes the incorporation and dispersion of the filler in a way that is impossible with dry mixing due to the potential degradation of the elastomer, such as natural rubber. The additional characteristic of the mixture being substantially free of rubber chemicals may provide a further improvement.Other advantages can be obtained when mixing a wet filler with a solid elastomer, compared to dry mixing, such as improved filler dispersion and / or facilitated interactions between the rubber and the filler and / or improved properties of the rubber compound.

[0150] Optionally, the elastomeric composite may be prepared by a process comprising: (a) load a mixer having one or more rotors with at least one solid elastomer and a wet charge comprising a filler and a liquid present in an amount of at least 15% by weight relative to the total weight of the wet charge; (b) in one or more mixing steps, mix the at least one solid elastomer and the wet charge to form a mixture and remove at least some of the liquid from the mixture by evaporation, and in at least one of said mixing steps, carry out said mixing in which at least one of the following conditions applies: (i) the mixer has at least one temperature control means which is set to a temperature, Tz, of 65 °C or higher, and (ii) the rotor(s) operate, for at least 50% of the mixing time, at a peak speed of at least 0.6 m / s; and (c) discharge from the mixer the composite comprising the filler dispersed in the elastomer at a rate of at least 20 phr, wherein the composite has a liquid content not exceeding 10% by weight relative to the total weight of said composite. The mixing may be carried out in one, two, three or more mixing stages.

[0151] Rubber chemicals, as defined herein, comprise one or more of the following: processing aids (to facilitate the mixing and processing of rubber, for example various oils and plasticizers, wax), activators (to activate the vulcanization process, for example oxide of zinc and fatty acids), accelerators (to speed up the vulcanization process, for example, sulfenamides and thiazoles), vulcanizing agents (or curing agents, to crosslink rubbers, for example, sulfur, peroxides), and other rubber additives, such as, but not limited to, retarders, co-agents, peptizers, adhesion promoters, tackifiers, resins, flame retardants, colorants, and blowing agents. Optionally, rubber chemicals may include processing aids and activators. Alternatively, the other rubber chemical(s) may be selected from zinc oxide, fatty acids, zinc salts of fatty acids, wax, accelerators, resins, and processing oil.

[0152] In the dry state, the fillers may contain no liquid or only small amounts of liquid (e.g., water or moisture) adsorbed onto their surface. For example, carbon black may contain 0% by weight, or from 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 herein as "dry fillers" or "unmoistened fillers." A "moist filler" comprises a filler and liquid present on a substantial part or virtually all of the filler's surfaces, which may include internal surfaces or pores accessible to the liquid. Thus, a sufficient quantity of liquid is supplied to moisten a substantial part or almost all of the surfaces of the filler before mixing with the solid elastomer.

[0153] 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.

[0154] 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 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 can have a boiling point at 1 atm of 180 °C. In some embodiments, the wet filler has the consistency of a solid.Optionally, a dry feedstock is moistened only to such an extent that the resulting wet feedstock retains the form of a powder, particles, granules, cake, or paste, or a similar consistency and / or appearance of a powder, particles, granules, cake, or paste. The wet feedstock does not flow like a liquid (at zero applied stress). Optionally, the wet feedstock can retain its shape at 25 °C when molded into such a form, whether as individual particles, agglomerates, granules, cakes, or pastes.

[0155] In certain embodiments, when mixing is carried out in the presence of a liquid (for example, a wet filler or a tackifier), the composite to be extruded may have a liquid content (for example, a moisture content when the liquid is water) of between 0.3% and 10% by weight, relative to the total weight of the composite. In certain embodiments, the liquid (moisture) content may be between 0.3% and 7%, between 0.3% and 5%, between 0.3% and 3%, between 0.3% and 2%, between 0.3% and 1%, between 0.5% and 10%, between 0.5% and 7%, between 0.5% and 5%, between 0.5% and 3%, between 0.5% and 2%, or between 0.5% and 1% relative to the total weight of the composite. The liquid content of the composite may depend on the mixing phase.For example, during a first mixing phase or a single-phase mix, the liquid content may be between 2% and 10%, between 2% and 7%, between 2% and 5%, between 2% and 3%, between 3% and 10%, between 3% and 7%, or between 3% and 5% by weight of the total composite. A subsequent mixing phase may reduce the liquid content to between 0.3% and 3%, between 0.3% and 2%, between 0.3% and 1%, between 0.5% and 3%, between 0.5% and 2%, or between 0.5% and 1% by weight of the total composite.

[0156] Another option is to prepare a substantially chemical-free rubber composite by mixing a filler suspension with an elastomer or an elastomer source in liquid form, for example, an elastomer solution, an emulsion, a latex, a coagulum, and the like. The elastomer or The elastomer source in liquid form can be mixed with the filler suspension in many ways known in the art, for example, by solution mixing. For example, the mixing may be a continuous mixing process comprising the introduction of a continuous flow of a first fluid comprising the elastomer solution, emulsion, latex, or coagulum into a mixing zone of a reactor (for example, an elongated mixing chamber) extending from the mixing zone to a discharge end. In another example, when the elastomer source is latex, the process may include: introducing a continuous flow of a first fluid comprising the latex elastomer into a mixing zone of a coagulation reactor, defining an elongated coagulation zone extending from the mixing zone to a discharge end; introducing a continuous flow of a second fluid comprising a pressurized particulate charge into the mixing zone of the coagulation reactor in order to form a mixture with the elastomeric latex, the mixture passing as a continuous flow to the discharge end and the particulate charge being effective in coagulating the elastomeric latex, wherein the introduction of the second fluid against the first fluid in the mixing zone is sufficiently energetic to coagulate substantially completely the elastomeric latex with the particulate charge before the discharge end, discharge a substantially continuous flow of elastomeric composite from the discharge end of the coagulation reactor.

[0157] In certain embodiments, the elastomeric composite or extrudate substantially free of rubber chemicals, or having a substantial absence of rubber chemicals, has a total amount of rubber chemicals less than 5 phr or less, 4 phr or less, 3 phr or less, 2 phr or less, 1 phr or less, or 0.5 phr or less, 0.2 phr or less, 0.1 phr or less.

[0158] In certain embodiments, the elastomeric composite can be characterized by a dynamic storage modulus of at least 900 kPa measured at a strain amplitude of 0.3%, G'(0.3%).

[0159] Current processing methods result in a form of extrudates, for example dimensions, curvature, etc., which allow further processing of the composite, for example compounding to include rubber chemicals after most of the filler has been dispersed in the elastomer.

[0160] In some embodiments, the elastomeric composite or extrudate consists or essentially consists of at least one solid elastomer and at least one filler. In some embodiments, the composite or extrudate may further comprise at least one anti-degrading agent (e.g., an antioxidant) and / or at least one tackifier. Consequently, in some embodiments, the The composite or elastomeric extrudate consists or essentially consists of at least one elastomer, at least one filler, and at least one anti-degrading agent. In other embodiments, the composite or elastomeric extrudate consists or essentially consists of at least one elastomer, at least one filler, and at least one tackifier. In still other embodiments, the composite or elastomeric extrudate consists or essentially consists of at least one elastomer, at least one filler, at least one anti-degrading agent, and at least one tackifier. These composites may be prepared by mixing a solid elastomer with a filler and a liquid (for example, a wet filler or a filler and liquid added separately) or by mixing a filler suspension with an elastomer or an elastomeric source in liquid form, for example, an elastomeric solution, a latex, an emulsion, and the like.

[0161] Thus, the elastomeric extrudate, as described herein, can be used to produce a product containing elastomer or rubber, for example, an elastomeric composite. In one embodiment, the elastomeric composite can be used or produced for use, for example, to form a vulcanizate intended to be incorporated into various parts of a tire, for example, treads, including the cap and base, the sub-tread, inner linings, sidewalls, carcasses, sidewall inserts, metal reinforcements for tires and cushioning rubbers for retreaded tires, in pneumatic tires as well as in non-pneumatic or solid tires.Alternatively or in addition, the elastomeric composite (and subsequently the vulcanizate) can be used for hoses, seals, gaskets, sealing strips, wipers, automotive components, coatings, pads, housings, wheel and track components, tire sidewall inserts, metal tire reinforcements, and cushioning rubber for retreaded tires, in pneumatic tires as well as in solid or non-pneumatic tires. Alternatively or in addition, the elastomeric composite (and subsequently the vulcanizate) can be used for hoses, seals, gaskets, anti-vibration components, tracks, and track pads for tracked equipment such as bulldozers, etc., engine mounts, seismic stabilizers, mining equipment such as screens, mining equipment liners, conveyor belts, chute liners, suspension pump liners, mud pump components such as impellers, valve seats, valve bodies, piston tips, piston rods, plunger pistons, impellers for various applications such as suspension mixing and suspension pump impellers, crusher liners, cyclones and hydrocyclones, expansion joints, marine equipment such as liners. For pumps (e.g., dredging pumps and outboard motor pumps), hoses (e.g., dredging hoses and outboard motor hoses) and other marine equipment, shaft seals for marine, oil and gas, aerospace and other applications, propeller shafts, linings for conveying pipelines, e.g., oil sands and / or tar sands, and other applications where abrasion resistance and / or improved dynamic properties are desired. Furthermore, the elastomeric composite, via vulcanized elastomeric composite, can be used in rollers, cams, shafts, pipes, bushings for vehicles, or other applications where abrasion resistance and / or improved dynamic properties are desired. EXAMPLES

[0162] These examples describe the preparation of elastomeric compositions comprising a filler, followed by extrusion and cutting. Preparation of elastomeric compositions

[0163] The elastomeric composites were prepared by mixing natural rubber (STR20) with a wet carbon black filler to obtain a filler content of 55 phr. 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 natural rubber used was standard grade STR20 natural rubber (Thailand). Technical descriptions of these natural rubbers are widely available, notably in the Blue Book of Rubber World magazine published by Lippincott and Peto, Inc. (Akron, Ohio, USA).

[0164] All the composites were prepared according to a two-stage mixing process. The first stage, consisting of mixing the wet filler and the elastomer, was carried out in a BB-16 tangential mixer (“BB-16”; Kobelco Kobe Steel Group) equipped with two 6-bladed tangential rotors (type 6WI), with a capacity of 14.4 l. Due to the steam released by the use of the wet filler, the mixer included an inlet and an outlet with a gas flow rate of 1095 Nm3 / h, as described in U.S. Provisional Application No. 63 / 707,346, filed on October 15, 2024, at [Fig. 1], and in the accompanying descriptions therein, including paragraph

[0106] , the description of which is incorporated herein by reference.

[0165] 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 was 90 kW, and the maximum output of the power PID control loop was set to 100 rpm. The power input signal used by the control loop The power PID 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 phase were: TCU temperature = 90 °C; filling factor = 66%; plunger pressure = 95 psig.

[0166] During the second phase, the composite from the first-phase mixture was combined with N-(1,3-dimethylbutyl)-N'-phenyl-p-phenylenediamine (6PPD, 2phr) in a BB-16 tangential mixer (“BB-16”) equipped with two 6-bladed tangential rotors under the following conditions: TCU temperature = 90 °C; fill factor = 44%; plunger pressure = 95 psig. The mixing was carried out with power PID control in which the proportional constant was 0.5% (step 5) and 1.25% (step 6), the integral constant was 0.1s, and no derivative control was used; the Kalman filter had a K2 constant of 0.005. The mixing procedures for phases 1 and 2 are shown in Tables 1 and 2, respectively, where “Duration” refers to the duration of each stage.The total mixing times for phases 1 and 2 were 8.7 min and 5 min respectively, resulting in composite moisture contents of 5.4 wt% and 0.3 wt% respectively. The probe temperatures were 119 °C for the phase 1 composites and 144 °C for the phase 2 composites. [Tables 1] Step Description Duration (°C) Temp (°C) Plunger Position RPM RPM (min) RPM (max) 1 Add 50% polymer - 75% filler - then the remaining 50% polymer - - High 50 - - 2 Mix until the target time or temperature is reached 20 120 Low 60 - - 3 Mix under power PID control until 125°C 125 Low 50 100 5 Reduce speed 10 - High 20 - - 6 Add the remaining 25% filler 20 - High 20 - - 7 Mix under power PID control until the specified temperature is reached 135 Low Power PID 50 110 8 Mix under power PID control until the specified temperature is reached 150 Low PID power 50 110 10 Ventilate the mixer 15 - Low 60 - - 11 Evacuate the mixer and close the hinged door 15 - Floating 50 - - Step Description Duration (s) Tem P-(°C) Plunger Position rpm rpm (min) rpm (max) 1 Introduce the master mix and the 6PPD - - High 35 - - 2 Mix the master mix 30 - Low 20 - - 3 Mix at a fixed speed with the plunger in the low position until the indicated temperature is reached 240 110 Low 20 - - 4 Raise the plunger - - High 20 - - 5 Mix under PI D power control until the indicated temperature is reached 130 High PID power 10 50 6 Mix under PI D power control until the indicated temperature is reached 135 High PID power 10 50 8 Remove the mixer and close the hinged door 30 - High 30 - - Extrusion of elastomeric compositions

[0167] The composites evacuated from the mixture of phases 1 and 2 were processed in a TSR-125 twin-screw evacuation extruder (Kobelco Kobe Steel Group), the twin screw of which is schematically shown in [Fig. 2] and the flat face of the screw is schematically shown in [Fig. 6C]. The twin screw was equipped with a die plate, as illustrated in Figures 3A to 3C. Tables 3 and 4 list the dimensions of the twin-screw extruder and the die plate, respectively. Twin-screw extruder Dimensions Inner diameter of TSR outlet 122.7 mm Outer diameter of rotor shaft 60 mm Maximum outer diameter of screw thread 110 mm Total outlet area 9505.3 mm² Total area of ​​screw thread flat face (Figure 6C) x 2 3684.2 mm² Screw thread flat face area / Total TSR outlet area 68.8% Screw flat face angle, a (Figure 6C) 90° Screw flat face distance, L (Figure 6C) 55 mm [Tables 4] Die plate dimensions: Thickness 17.5 mm; Die plate length 405 mm; Die plate width 190 mm; Slot angle [3 (Figure 3A)] 37.5°; Maximum outside diameter of knife holes 110 mm; Number of holes / twin screw (2 x 8) 16; Radial width of each hole 9.3 mm; Circumferential length of each hole 35.4 mm; Area of ​​each hole 311 mm²; Total area of ​​holes 4970.5 mm²

[0168] Extrusion was carried out using a set of twin-screw rotors, where the TCU temperature was set to 90 °C, the die plate to a temperature of 150 °C, and the extruder rotated at 32.5 rpm. Photographs of the resulting extrudates are shown in Figures 10A (1st phase) and 10B (2nd phase). The length and The width of the extradate was determined using the ImageJ software available at https: / / imagej.net / in accordance with ISO 9276-6:2008.

[0169] Representative extrudates were prepared for image analysis, as shown in the photographs in Figures 1IA (Phase 1) and 1IB (Phase 2). These extrudates were also used to measure the thickness manually, along and through the extrudate, using calipers. To measure the angle of curvature, the contours of each extrudate were obtained, and their fitted ellipses were calculated using ImageJ software. The extrudate contours and corresponding ellipses are shown in Figures 12A and 12B for the Phase 1 composites, and in Figures 13A and 13B for the Phase 2 composites. The angle of curvature was calculated as shown in [Fig. 8A] and in the accompanying discussion.

[0170] Table 5 summarizes the length, width, thickness and angle of curvature of the phase 1 and phase 2 composites. [Tables 5] Composite Measurement Minimum Maximum 75th percentile 90th percentile Phase 1 Length (mm) 21.1 443.2 133.8 287.1 Phase 1 Width (mm) 8.2 232.7 57.9 122.3 Phase 2 Length (mm) 23.1 166.4 86.3 116.5 Phase 2 Width (mm) 15.7 109.3 53.4 65.4 Phase 1 Thickness (mm) 5.0 7.9 6.5 7.7 Phase 2 Thickness (mm) 5.1 8.5 7.5 8.1 Phase 1 Angle of curvature (degrees) 96.9 166.5 159.1 164.8 Phase 2 Angle of curvature (degrees) 98.3 156.4 143.2 152

[0171] It can be observed that all the extrudates had a maximum dimension (length) of less than 500 mm, and 90% of the extrudates had a length of less than 300 mm. The angle of curvature of at least 75% of the extrudates was less than 160°. It can be observed that the amount of water influences the size of the extrudates: the extrudates from the first phase, which had a higher moisture content, had greater lengths, widths, and angles of curvature than the extrudates from the second phase. The extrudates from the second phase had a lower moisture content, which resulted in smaller dimensions and angles of curvature. generally weaker. The examples demonstrate that the invention claimed herein is effective for extruding and cutting elastomeric composites, such as moisture-containing composites and / or composites having a substantial absence of rubber chemicals, to form extrudates having a maximum dimension (length) not exceeding 500 mm and in which at least 75% of the extrudates have a curvature angle not exceeding 160°. Balls

[0172] The density of the phase 1 extrudates was determined to be 1110 kg / m³. The weight of extrudates required to fill a metal container with a volume of 0.018 m³ was 5.6 kg. Theoretically, the bag containing the solid extrudate would weigh 20 kg. Thus, the volume filled by 5.6 kg of extrudates was 18%; conversely, the void volume was 72%. In contrast, the void volume obtained with extrudates cut using a granulator that cuts the sheets into frits was a maximum of 40%. It can be observed that extrudates cut according to the current processes yielded bales with a much greater void volume than those obtained with previous processes. Appendix 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 input, 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 processing a composition, the method comprising: introducing the composition into a screw extruder, in which the composition comprises at least one elastomer and at least one filler; and extruding the composition through the extruder by applying a shear force to the composition;and extrude the composition through a fixed die provided at one outlet end of the extruder, wherein the extrusion comprises: forcing the composition through at least one non-circular slot extending through a die body of the fixed die from a first face of the die body to an opposite face of the die body which is opposite the first face, thus forming a passage such that the composition is forced through an inner surface of the at least one non-circular slot, wherein the inner surface is conical such that a first opening at one of the first or opposite faces is smaller than a second opening at the other of the first or opposite faces.

2. A method for processing a composition, the method comprising: introducing the composition into a screw extruder, wherein the composition comprises at least one elastomer and at least one filler; extruding the composition through the extruder by applying a shear force to the composition; and extruding the composition through a fixed die provided at an outlet end of the extruder, wherein the extrusion comprises: forcing the composition through at least one slot extending through a die body of the fixed die from a first face of the die body to an opposite face of the die body that is opposite the first face, thus forming a passage such that the composition is forced through an inner surface of the at least one slot, wherein the inner surface is conical. such that a first opening at the level of one of the first face or the opposite face is smaller than a second opening at the level of the other of the first face or the opposite face, and in which the first and second openings are non-concentric.

3. A method for processing a composition, the method comprising: introducing the composition into a screw extruder, wherein the composition comprises at least one elastomer and at least one filler having a filler ratio of at least 20 phr, wherein the composition is substantially free of rubber chemicals; extruding the composition through the extruder by applying a shear force to the composition; extruding the composition through a die provided at an outlet end of the extruder, wherein the die comprises a die body having a first face and an opposite face, wherein the extrusion comprises passing the composition through at least one slot extending through the die body from the first face to the opposite face which forms a passage;and cut the extruded composition using an associated die blade, wherein one or more of the die and associated blade are rotating.

4. A method according to claim 3, wherein an inner surface of the slot is conical such that a first opening at one of the first face or the opposite face is smaller than a second opening at the other of the first face or the opposite face.

5. A method according to any one of claims 1 to 4, wherein the composition has a charge ratio of at least 20 phr, and the composition has a dynamic storage modulus of at least 900 kPa measured at a strain amplitude of 0.3%, G'(0.3%), at a frequency of 1 Hz and at 100 °C.

6. A method according to any one of claims 1 or 3, wherein the first and second openings are non-concentric.

7. A method according to any one of claims 1 or 3, wherein the first and second openings are concentric.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19. A method according to any one of claims 1 to 6, wherein the screw extruder is a single-screw or twin-screw extruder. A method according to any one of claims 1, 2, and 4 to 8, wherein the first opening is located on the first face such that the slot is outwardly conical. A method according to any one of claims 1, 2 and 4 to 8, wherein the first opening is located on the opposite face so that the slot is conical inwards. A method according to any one of claims 1 to 10, wherein the taper of the inner surface of at least one slot is configured to hold the composition on a cutting edge of at least one slot which aligns substantially with a direction of a vector combining tangential and radial forces imposed on the composition extruded through the die. A method according to any one of claims 1 to 11, wherein at least one wall of the inner surface of the slot is substantially flat, concave or convex. A method according to any one of claims 1 to 12, wherein at least one wall of the conical inner surface of at least one slot is beveled. A method according to any one of claims 1 to 13, wherein a cross-section of the inner surface of the slot defines a taper angle between 20° and 60°. A method according to any one of claims 1 to 14, wherein at least one slot defines an open surface covering 20% ​​to 60% of the total surface area of ​​the first face or the opposite face. A method according to any one of claims 1 to 15, wherein at least one slot has a radial length-to-circumferential width ratio of between 1.1:1 and 10:

1. A method according to any one of claims 1 to 16, wherein at least one slot is configured to align substantially with a direction of a vector combining tangential and radial forces on the composition extruded through the die from the extruder. A method according to any one of claims 1 to 17, wherein at least one slot has an elongated shape. A method according to any one of claims 1 to 17, wherein at least one slot has an elliptical or oval shape.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32. A method according to any one of claims 1 to 17, wherein at least one of the first and second openings of at least one slot has a stadium shape with two parallel linear edges. A method according to any one of claims 18 to 20, wherein a central line aligned with the longest dimension of at least one slot is offset from an axial axis of a corresponding screw of the extruder. A method according to any one of claims 18 to 20, wherein a central line aligned with the longest dimension of at least one slot is offset from an axial axis of a corresponding screw of the extruder by an angle between 20° and 50°. A method according to any one of claims 1 to 17, wherein at least one slot is bean-shaped. A method according to any one of claims 1 to 23, wherein at least one slot has at least one wavy or serrated cutting edge. A method according to any one of claims 1 to 23, wherein at least one slot has at least one straight cutting edge. A method according to any one of claims 1 to 25, wherein at least one slot comprises a plurality of slots. A method according to any one of claim 26, wherein a number of sets of the plurality of slots corresponds to a number of screws provided in the extruder. A method according to claim 26 or 27, wherein a midpoint of each set of the plurality of slots is aligned substantially coaxially with the corresponding screw provided in the extruder. A method according to any one of claims 1 to 28, wherein at least one slot comprises from 1 to 100 slots. A method according to claim 3, wherein the associated blade has at least one of a linear, circular, wavy, or serrated edge. A method according to claim 30, wherein the associated blade is external to the die and configured to cut the extruded composition as the extruded composition exits the die. Method according to claim 30, wherein the associated blade is at least one edge of at least one opening of the die.

33. A method according to any one of claims 1 to 32, further comprising a heating element for heating the composition extruded through the die, wherein the heating element is configured to be heated to a temperature between 90 °C and 150 °C.

34. A method according to any one of claims 1 to 33, wherein a clearance between the die and the screw extruder is between 0.5 mm and 5.0 mm.

35. A method according to any one of claims 1 to 34, wherein the flow of the composition through the extruder occurs at a flow rate between 0.0005 m3 / min and 1.0 m3 / min.

36. A method according to any one of claims 1 to 34, wherein the flow of the composition through the extruder occurs at a flow rate of between 0.5 kg / min and 1,000 kg / min, wherein the density of the extrudate is between 0.90 and 1.

3.

37. A method according to any one of claims 1 to 36, wherein the composition is extruded through the outlet end at an outlet speed of between 0.05 m / min and 30 m / min.

38. A method according to any one of claims 1 to 37, wherein the screw or twin screws of the extruder rotate at a speed between 5 rpm and 50 rpm.

39. A method according to any one of claims 1 to 38, wherein the extruder is configured to maintain a metal temperature of the single-screw or twin-screw extruder between 50 °C and 150 °C.

40. A method according to any one of claims 1 to 39, wherein the composition is an elastomeric composite.

41. A method for processing a composite in an integrated manufacturing operation, comprising: introducing the composite into a screw extruder; forcing the composite through the extruder by applying a shear force to the composition; and extruding the composite through a die provided at one outlet end of the extruder so that the extruded composite has an irregular shape.

42.

43. Extruded product according to any one of claims 1 to 41. Process for treating a composition, the process comprising: introducing the composition into a screw extruder, wherein the composition comprises at least one elastomer and at least one filler; extruding the composition through the extruder by applying a shear force to the composition, wherein the screw or screws of the extruder each comprise (i) a shaft having a longitudinal axis, a first end, and a second outlet end, and (ii) a screw thread provided on the shaft along the longitudinal axis from the first end to the second outlet end to apply the shear force to the composition;and extrude the composition through a die provided at the second outlet end of each screw or screws of the extruder, wherein the second outlet end has an end portion with a flat face formed by the shaft and the screw thread, and wherein the flat face has an area between 20% and 70% of an area defined by an outside diameter of the screw thread.

44. Method according to claim 43, wherein the screw is conical and the area of ​​the flat face is between 20% and 70% of the area defined by the maximum outside diameter of the screw thread.

45. Method according to claim 43, wherein the screw is conical and the area of ​​the flat face is between 20% and 70% of the area defined by the outside diameter of the screw thread at the second exit end.

46. A method according to any one of claims 43 to 45, wherein the area of ​​the flat face is between 20% and 70% of the area defined by the outside diameter of the screw thread.

47. A method according to any one of claims 43 to 46, wherein the flat face has a geometry having a circular part and a wedge-shaped part which is at least partially formed by the screw thread, wherein a dimension of the wedge-shaped part with respect to the center of the circular part is at least 70% of a radius formed by a widest dimension of the screw thread.

48. Method according to claim 47, wherein the wedge-shaped part defines a sector having an angle between 20° and 100°.

49. A method according to any one of claims 43 to 48, wherein the end part having the flat face is formed by a truncation of the second end of the shaft.

50. A method for processing a composition, the method comprising: introducing the composition into a screw extruder, wherein the composition comprises at least one elastomer and at least one filler; and extruding the composition through the extruder by applying a shear force to the composition, wherein the screw or screws of the extruder each comprise (i) a shaft having a longitudinal axis, a first end, and a second output end, and (ii) a screw thread provided on the shaft along the longitudinal axis from the first end to the second output end for applying the shear force to the composition;and extrude the composition through a die provided at the second outlet end of the screw or screws, wherein the second outlet end has an end portion with a flat face formed by the screw shaft and thread, and wherein at least a portion of the flat face is configured to have an area between 0.9 and 3 times the area of ​​a slot in an extruder die.

51. A method according to claim 50, wherein at least a portion of the flat face is configured to align with the slot so that at least a portion of the flat face covers the entire slot of the die with each rotation of the screw.

52. A method according to claim 50, wherein at least a portion of the flat face has an area between 0.9 and 2 times the area of ​​the slot.

53. A method according to any one of claims 43 to 52, wherein the extruder die comprises a plurality of slots.

54. A method according to any one of claims 43 to 53, wherein the shaft is tapered from the first end to the second end, wherein the second end is narrower than the first end.

55. A method according to any one of claims 43 to 54, wherein the thickness of the end part having the flat face is between 5 mm and 15 mm.

56. A method according to any one of claims 43 to 55, wherein the extruder is a twin-screw extruder and comprises twin screws provided as a pair of meshed screws.

57. A method according to any one of claims 43 to 56, wherein the extruder is a twin-screw extruder and comprises twin screws tapered towards each other.

58. A method according to any one of claims 43 to 57, wherein the screw or screws are configured to heat and / or cool the elastomer material.

59. A method according to any one of claims 1 to 41, wherein the screw or screws of the extruder each comprise (i) a shaft having a longitudinal axis, and (ii) a screw thread provided on the shaft along the longitudinal axis, wherein, near the exit end of the extruder, there is an end portion of the screw or screws having a flat face formed by the shaft and the screw thread, and wherein the flat face has an area between 20% and 70% of an area defined by an outside diameter of the screw thread.

60. A method according to any one of claims 1 to 41, wherein the screw or screws of the extruder each comprise (i) a shaft having a longitudinal axis, and (ii) a screw thread provided on the shaft along the longitudinal axis, wherein, near the exit end of the extruder, there is an end portion of the screw or screws having a flat face formed by the shaft and the screw thread, and wherein the flat face is configured to have an area between about 0.9 and 3 times the area of ​​at least one slot.

61. A process according to any one of claims 1 to 60, wherein the composition has a liquid content of between 0.3% and 10%.

62. A method according to any one of claims 1 to 61, wherein the composition essentially consists of: i. at least one elastomer and at least one filler, or ii. at least one elastomer, at least one filler and at least one anti-degradant, or iii. at least one elastomer, at least one filler and at least one tackifying agent, or iv. at least one elastomer, at least one filler, at least one anti-degradant and at least one tackifying agent.

63. A method according to any one of claims 1 to 60, wherein the composition consists of: i. at least one elastomer and at least one filler, or ii. at least one elastomer, at least one filler and at least one anti-degradant, or iii. at least one elastomer, at least one filler and at least one tackifier, or iv. at least one elastomer, at least one filler, at least one anti-degradant and at least one tackifier.

64. Extrudate Elastomeric extrudate comprising at least one elastomer and at least one filler in a quantity of at least 20 phr, wherein the extrudate has: a length not exceeding 500 mm; and an angle of curvature in at least one dimension between 50° and 160°.

65. Extrudate elastomer extrudate according to claim 64, wherein the extrudate extrudate has a main body part which has an angle of curvature in at least one dimension between 50° and 160°.

66. Extrudate elastomer extrudate according to claim 64 or 65, wherein the extrudate extrudate further comprises a width, wherein the aspect ratio between the length and the width of the extrudate extrudate is between 1.5:1 and 5:

1.

67. Extrudate elastomer extrudate according to any one of claims 64 to 66, wherein the angle of curvature is in at least two dimensions.

68. Extrudate Elastomer extrudate according to claim 67, wherein the extrudate has a spoon shape.

69. Extrudate Elastomer extrudate according to any one of claims 64 to 68, wherein the extrudate has a thickness between 2 mm and 25 mm.

70. Extrudate Elastomer extrudate according to any one of claims 64 to 69, wherein the width of the extrudate is between 20 and 300 mm.

71. Extrudate Elastomeric extrudate according to any one of claims 64 to 70, wherein the extrudate has an area between 0.0005 and 0.01 m2.

72. Extrudate Elastomeric extrude according to any one of claims 64 to 71, wherein at least one elastomer is selected from natural rubber, functionalized natural rubber, styrene-butadiene rubber, functionalized styrene-butadiene rubber, polybutadiene rubber, functionalized polybutadiene rubber, polyisoprene rubber, ethylene-propylene rubber, isobutylene-based elastomers, halogenated butyl rubber, polychloroprene rubber, nitrile rubber, hydrogenated nitrile rubber, polysulfide rubber, polyacrylate elastomers, fluoroelastomers, perfluoroelastomers, silicone elastomers, and mixtures thereof.

73. Extrudate Elastomer extrudate according to any one of claims 64 to 72, wherein the elastomer extrudate comprises at least 50% natural rubber.

74. Extrudate Elastomer extrudate according to claim 73, wherein the elastomer extrudate further comprises at least one of styrene-butadiene rubber and polybutadiene rubber.

75. Extrudate Elastomeric extrude according to any one of claims 64 to 74, wherein the filler is selected from carbon black, carbon materials, silica, nanocellulose, lignin, clays, nanoclays, metal oxides, metal carbonates, pyrolysis carbon, graphene, graphene oxides, reduced graphene oxide, carbon nanotubes, single-walled carbon nanotubes, multi-walled carbon nanotubes, carbon nanostructures, fragments of carbon nanostructures or fractured multi-walled carbon nanotubes, or combinations thereof, and materials coated and treated from the same.

76.

77.

78.

79.

80.

81.

82. Extrudate Elastomeric extrusion according to any one of claims 64 to 74, wherein the filler is selected from carbon black, silica, silicon-treated carbon black, and combinations thereof. Extruded elastomer extrudate according to any one of claims 64 to 74, wherein the filler is carbon black. Extruded elastomer extrudate according to any one of claims 64 to 74, wherein the filler is silica. Extruded elastomer extrudate according to any one of claims 64 to 74, wherein the filler is a mixture comprising carbon black and silica. Extruded elastomer according to any one of claims 64 to 79, wherein the extruded elastomer is substantially free of rubber chemicals. Extruded elastomer according to any one of claims 64 to 79, wherein the extruded elastomer consists essentially of: i. at least one elastomer and at least one filler, or ii. at least one elastomer, at least one filler and at less an anti-degrader, or iii. at least one elastomer, at least one filler and at least one tackifier, or iv. at least one elastomer, at least one filler, at least one anti-degrader and at least one tackifier. Extrudate elastomer extrudate according to any one of claims 64 to 79, wherein the extrudate elastomer extrudate consists of: i. at least one elastomer and at least one filler, or ii. at least one elastomer, at least one filler and at less an anti-degrader, or iii. at least one elastomer, at least one filler and at least one tackifier, or iv. at least one elastomer, at least one filler, at least one anti-degrader and at least one tackifier.

83. Extrudate elastomer extrudate according to any one of claims 64 to 82, wherein the extrudate extrudate has a dynamic storage modulus of at least 900 kPa measured at a strain amplitude of 0.3%, G'(0.3%), at a frequency of 1 Hz and at 100° r

84. V-. Extrudate Elastomer extrudate according to any one of claims 64 to 83, wherein the elastomer extrudate is formed by extruding an elastomer composition through a screw extruder, which may be a single screw or twin screw extruder.

85. Extrudate Elastomer extrudate according to claim 84, wherein the single-screw or twin-screw extruder is configured to expel the material by applying a shear force to the material, the extruder further comprising: a die provided at an outlet end of the single-screw or twin-screw extruders for extruding the material, wherein the die comprises: a fixed die body, a first face of the die body, an opposite face of the die body which is opposite to the first face, and at least one slot extending through the die body from the first face to the opposite face, thus forming a passage, wherein the at least one slot has an inner surface which is conical such that a first opening at one of the first or opposite faces is smaller than a second opening at the other of the first or opposite face,in which at least one slot is configured to align substantially with a direction of a vector combining tangential and radial forces imposed on the material extruded through the die from the extruder.

86. Plurality of elastomeric extrudates comprising the elastomeric extrudate according to any one of claims 64 to 85.

87. A plurality of elastomeric extrudates, each having an irregular shape and comprising at least one elastomer and at least one filler in an amount of at least 20 phr, wherein: at least 75% of the plurality of extrudates have a length not exceeding 500 mm; and at least 75% of the plurality of elastomeric extrudates have a curvature angle in at least one dimension between 50° and 160°.

88. A plurality of elastomeric extrudates according to claim 87, wherein at least 90% of the plurality of extrudates have a curvature angle in at least one dimension between 50° and 160°.

89. A plurality of elastomeric extrudates according to any one of claims 86 to 88, wherein at least 75% of the plurality of extrudates have a width, wherein the aspect ratio between the length and width of the extrudate is between 1.5:1 and 5:

1.

90. Ball comprising the plurality of elastomeric extrudates according to any one of claims 86 to 89, wherein the ball has a void volume of between 50% and 90%.

91. A method for extruding a material, the method comprising: introducing the material into a screw extruder; making the material flow through the extruder by applying a shear force to the material; extruding the material through a die plate provided at an outlet end of the extruder, wherein the elastomeric extrudate has an irregular shape, wherein the extrudate has an angle of curvature in at least one dimension between 50° and 160°, and wherein the length of the extrudate is not greater than 500 mm.

92. Method according to claim 91, wherein the material comprises an elastomer and a filler at a rate of at least 20 phr.

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