Micronized recycled rubber compositions

Abstract

Disclosed herein are recycled rubber materials, methods, and systems for producing the same. In some aspects, the present disclosure is directed to recycled rubber materials include micronized rubber particle compositions and uncured virgin rubber compositions. In some aspects, the present disclosure is directed to methods including obtaining previously cured rubber materials, granulating (e.g., micronizing) previously cured rubber materials to generate micronized rubber particle compositions, and mixing micronized rubber particle compositions with uncured rubber compositions, such as uncured virgin rubber compositions. In some aspects, the present disclosure is directed to systems useful for performing disclosed methods and for preparing disclosed recycled rubber materials.

Description

Attorney Docket No.: 2006702-0042 RECYCLED RUBBER COMPOSITIONS CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Application Serial No.63 / 529625 filed on July 28, 2023, the disclosure which is hereby incorporated by reference in its entirety. BACKGROUND

[0002] Every year, millions of tires and other rubber materials end up in being discarded and end up in landfills (The User Guidelines for Waste and Byproduct Material in Pavement Construction report from the US Department of Transportation, Federal Highway Administration [www.fhwa.dot.gov / publication s / research / infrastructure / structures / 97148 / st1.cfm]). In production facilities for making these rubber products, greater than 25% of the rubber material is discarded as scraps and trim. Given the volume of this waste, recycling these materials is advantageous both for the environment and rubber manufacturers. However, recycling rubber materials has proven challenging, as rubber materials (e.g., tires and floor surfaces) are cured through a vulcanization process where the rubber becomes cross-linked with sulfur. Such materials are difficult to recycle into new rubber materials. SUMMARY

[0003] The present disclosure provides, among other things, recycled rubber materials where previously used rubber materials that would have normally been discarded (e.g., scrap materials and worn-out rubber products) are processed into a micronized rubber particles and combined with virgin (e.g.., uncured) rubber compositions. Additionally, the present disclosure encompasses the recognition of a problem with recycling rubber materials. For example, conventional methods and systems require using de-vulcanization materials to properly incorporate previously used rubber materials with virgin rubber compositions. Accordingly, in some embodiments, the present disclosure provides for methods and / or systems which do not require using de-vulcanization materials. The methods presented in the disclosure provide an efficient process for generating micronized rubber particles from various rubber compositions and incorporating them into uncured rubber compositions (e.g., uncured virgin rubber compositions) in order to produce recycled rubber compositions and Page 1 of 60 12187367v1Attorney Docket No.: 2006702-0042 materials. Resulting recycled rubber materials are shown to have substantially similar physical properties compared to the same rubber material without the recycled component.

[0004] After reading the present disclosure, one of skill in the art will appreciate that disclosed embodiments provide advantages over traditional methods and techniques for recycling rubber materials. For example, without wishing to be bound by any particular theory, preparing recycled rubber materials in accordance with embodiments of the present disclosure provides advantages such as reduced water usage and / or incorporation of undesirable content of water into recycled rubber materials. For example, reducing water usage in preparation of recycled rubber materials provides more efficient processes, and / or avoids requirements for additional steps such as drying to remove water. As another example, reducing water content in recycled rubber materials reduces undesirable defects in recycled rubber materials, such as, among other things, bubbling, cracking, etc. Additionally or alternatively, preparing recycled rubber materials in accordance with embodiments of the present disclosure provides for reduced use of potentially undesirable chemicals, such as rubber de-linking accelerators.

[0005] Accordingly, in some embodiments, preparation of disclosed recycled rubber materials does not require use of disadvantageous techniques or systems for granulating rubber materials, such as water jets and / or cryogenic systems, which are disadvantageously cost-prohibitive and do not provide micronized rubber particles in accordance with various embodiments of the present disclosure. Further, such exemplary systems mitigate potential contamination of recycled rubber materials with water. Accordingly, in some embodiments, methods for preparing recycled rubber materials do not require removing water from micronized rubber particle compositions. For example, in some embodiments, methods for preparing recycled rubber materials do not comprise drying micronized rubber particle compositions and / or mixtures or materials which comprise micronized rubber particle compositions.

[0006] Additionally or alternatively, in some embodiments, preparation of disclosed recycled rubber materials does not require use of de-linking materials and / or compositions for recycling exemplary rubber materials. For example, methods for preparing recycled rubber materials do not comprise de-vulcanizing micronized cured rubber particle compositions. Accordingly, in some embodiments, disclosed recycled rubber materials and / or compositions are substantially free of rubber de-linking accelerators, for example de-vulcanization Page 2 of 60 12187367v1Attorney Docket No.: 2006702-0042 chemicals. In some embodiments, exemplary recycled rubber materials and / or compositions which are substantially free of rubber de-linking accelerators comprise de-linking accelerators in a proportion less than about 15 wt%, less than about 10 wt%, less than about 5 wt%, less than about 4 wt%, less than about 3 wt%, less than about 2 wt%, less than about 1 wt%, less than about 0.5 wt%, or less than about 0.1 wt%. Exemplary de-linking accelerators may be or comprise zinc salts of thiocarbamates, zinc salts of dialkyl dithiophosphates, 2- mercaptobenzothiazole, derivatives of 2-mercaptobenzothiazole, thiurams, guanidines, 4,4’dithiomorpholine, sulphenamides, hexamine, and any combination thereof.

[0007] In one aspect, the present disclosure is directed to methods for producing a recycled rubber material, the methods comprising: (i) obtaining a previously cured rubber material; (ii) granulating (e.g., micronizing) the previously cured rubber material in order to generate a composition of micronized cured rubber particles; and (iii) mixing the composition of micronized cured rubber particles with an uncured rubber composition (e.g., an uncured virgin rubber composition).

[0008] In some embodiments, methods further comprise screening compositions of micronized cured rubber particles to produce a composition of micronized cured rubber particles having a particular particle size distribution.

[0009] In some embodiments, methods do not comprise screening compositions of micronized cured rubber particles.

[0010] In some embodiments, methods further comprise performing a partial or complete de-vulcanization of compositions of micronized cured rubber particles.

[0011] In some embodiments, methods do not comprise performing a partial or complete de-vulcanization of compositions of micronized cured rubber particles.

[0012] In some embodiments, methods further comprise curing mixtures of micronized cured rubber particles and uncured rubber material.

[0013] In some embodiments, mixtures comprise at least about 5 wt%, at least about 10 wt%, at least about 15 wt%, at least about 20 wt%, at least about 25 wt%, at least about 30 wt%, at least about 40 wt%, or at least about 50 wt% of compositions of micronized cured rubber particles.

[0014] In some embodiments, at least 90% of micronized cured rubber particles have a particle size less than about 5600 µm, less than about 4750 µm, less than about 4000 µm, less than about 3350 µm, less than about 3170 µm, less than about 2800 µm, less than about Page 3 of 60 12187367v1Attorney Docket No.: 2006702-0042 2360 µm, less than about 2000 µm, less than about 1700 µm, less than about 1400 µm, less than about 1180 µm, less than about 1000 µm, less than about 850 µm, less than about 710 µm, less than about 600 µm, less than about 500 µm, less than about 425 µm, less than about 355 µm, less than about 300 µm, or less than about 250 µm.

[0015] In some embodiments, at least 99% of micronized cured rubber particles have a particle size of about 1000 µm or less, about 965 µm or less, about 950 µm or less, about 880 µm or less, about 800 µm or less, about 743 µm or less, about 697 µm or less, about 558 µm or less.

[0016] In some embodiments, at least 50% of micronized cured rubber particles have a particle size of about 350 µm or less, about 325 µm or less, about 305 µm or less, about 300 µm or less, about 242 µm or less, about 159 µm or less.

[0017] In some embodiments, the Sauter mean diameter (SMD) of micronized cured rubber particles is about 500 µm or less, about 400 µm or less, about 300 µm or less, about 250 µm or less, about 236 µm or less, about 180 µm or less, about 165 µm, about 132 µm or less.

[0018] In some embodiments, particle sizes and / or particle size distributions are characterized by sieve analysis (e.g., in accordance with ASTM D5644) and / or laser diffraction particle size analysis (e.g., using a Malvern Mastersizer, using a QICPIC® system from Sympatec).

[0019] In some embodiments, mixtures comprising compositions of micronized cured rubber particles and uncured rubber material are substantially free of de-linking accelerators (e.g., de-vulcanization chemicals).

[0020] In some embodiments, previously cured rubber materials comprise natural rubber and / or at least one synthetic rubber. In some embodiments, at least one synthetic rubber comprises one or more members selected from the group consisting of: styrene- butadiene rubber (SBR), nitrile rubber (e.g., acrylonitrile butadiene rubber), ethylene propylene diene monomer rubber (EPDM), synthetic polyisoprene (e.g., cis-1,4- polyisoprene), chloroprene rubber, butyl rubber, butadiene rubber, ethylene propylene rubber, fluoro-rubber, silicone rubber, and thermoplastic elastomer.

[0021] In some embodiments, uncured rubber compositions comprise natural rubber and / or at least one synthetic rubber. In some embodiments, at least one synthetic rubber comprises one or more members selected from the group consisting of: styrene-butadiene Page 4 of 60 12187367v1Attorney Docket No.: 2006702-0042 rubber (SBR), nitrile rubber (e.g., acrylonitrile butadiene rubber), ethylene propylene diene monomer rubber (EPDM), synthetic polyisoprene (e.g., cis-1,4-polyisoprene), chloroprene rubber, butyl rubber, butadiene rubber, ethylene propylene rubber, fluoro-rubber, silicone rubber, and thermoplastic elastomer.

[0022] In some embodiments, uncured rubber compositions further comprise one or more additional components selected from the group consisting of: clay, carbon-black, aromatic process oil, zinc oxide, antioxidant, additives, sulfur, accelerators, calcium carbonate, naphthenic process oil, and silica.

[0023] In some embodiments, granulating occurs at a rate within a range of about 0.5 ft / min to about 20 ft / min, about 1 ft / min to about 15 ft / min, about 3 ft / min to about 10 ft / min, or about 6 ft / min to about 7 ft / min (e.g., wherein previously cured rubber materials are granulated at a rate within a range of about 0.5 ft / min to about 20 ft / min, about 1 ft / min to about 15 ft / min, about 3ft / min to about 10 ft / min, or about 6 ft / min to about 7 ft / min).

[0024] In some embodiments, granulating comprises abrading previously cured rubber materials with an abrading wheel, the abrading wheel (e.g., an abrading wheel comprising steel, such as A36 steel) comprising an abrasive having a grit of at most about 200, at most about 100, at most about 80, at most about 60, at most about 50, at most about 40, or at most about 20.

[0025] In some embodiments, abrasives comprise one or more members selected from the group consisting of diamond, aluminum oxide, corundum, zirconium, ceramics, silicon carbide, and any combination thereof.

[0026] In some embodiments, abrading wheels operate at a speed of at least about 500 rpm, at least about 1000 rpm, at least about 1500 rpm, at least about 2000 rpm, at least about 2500 rpm, at least about 3000 rpm, at least about 3500 rpm, at least about 4000 rpm, at least about 4500 rpm, or at least about 5000 rpm.

[0027] In some embodiments, abrading comprises presenting previously cured rubber materials to abrading wheels at an angle within a range of about 15°-75°, within a range of about 20°-70°, within a range of about 25°-65°, within a range of about 30°-60° within a range of about 35°-55°, or within a range of about 40°-50°.

[0028] In some embodiments, abrading comprises presenting previously cured rubber materials to an abrading wheel at an angle of about 30° to about 45°. Page 5 of 60 12187367v1Attorney Docket No.: 2006702-0042

[0029] In some embodiments, abrading comprises presenting the previously cured rubber material to the abrading wheel via a rubber trim feed system.

[0030] In some embodiments, a gap is present between the abrading wheel and the rubber trim feed system, the gap being within a range of about 0.001 inches and about 0.01 inches, or about 0.003 inches and about 0.008 inches. In some embodiments, one or more systems are used to maintain the gap between the abrading wheel and the rubber trim feed system.

[0031] In some embodiments, methods comprise maintaining a temperature of the abrading wheel during abrading (e.g., by cooling). In some embodiments, abrading comprises presenting the previously cured rubber material to the abrading wheel via a rubber trim feed system.

[0032] In some embodiments, there is a gap between an abrading wheel and a rubber trim feed system, the gap being within a range of about 0.001 inches and about 0.01 inches, or about 0.003 inches and about 0.008 inches.

[0033] In some embodiments, methods comprise cooling and / or heating a surface of the abrading wheel during abrading to maintain a temperature within 20°C, within 10°C, within 5°C, within 4°C, within 2°C of an initial (e.g., a pre-determined) temperature.

[0034] In another aspect, the present disclosure is directed to a recycled rubber material produced by methods of any one of the embodiments disclosed herein.

[0035] In some embodiments, recycled rubber materials are characterized as having substantially similar physical properties as a reference cured rubber material (e.g., wherein the reference cured rubber material is the same cured rubber material that does not undergo disclosed methods, e.g., wherein the reference cured rubber material is a cured virgin rubber material).

[0036] In some embodiments, differences in physical properties between recycled rubber materials and the reference cured rubber material measured by one or more tests is less than 50%, less than 40%, less than 30%, less than 20%, less than 10%, or less than 5% different.

[0037] In some embodiments, one or more tests comprises one or more members selected from the group consisting of: Density (ASTM D-297), Durometer Shore A (ASTM D-2240), Tensile Strength at Break (ASTM D-412), Elongation (ASTM D-412), Compressive Stress Test (ASTM D-624 or ASTM D-395), Tear strength (ASTM D-624), Cold Flexibility Page 6 of 60 12187367v1Attorney Docket No.: 2006702-0042 (ASTM D-2137 or ASTM D-746B), Abrasion NBS (ASTM D-1630), Oil resistance (ASTM D471), Heat Ageing (ASTM D573) and Cold Resistance (ASTM D2137).

[0038] In some embodiments, the recycled rubber material is characterized as having substantially similar ozone resistance properties as a reference cured rubber material (e.g., wherein the reference cured rubber material is the same cured rubber material that does not undergo a method for producing a recycled rubber material as described above, e.g., wherein the reference cured rubber material is a cured virgin rubber material). In some embodiments, the ozone resistance properties are measured by an ozone resistance test (ASTM D1171).

[0039] In some embodiments, recycled rubber materials are characterized as having substantially similar visual properties as a reference cured rubber material (e.g., wherein the reference cured rubber material is the same cured rubber material that does not undergo a method as disclosed herein, e.g., wherein the reference cured rubber material is a cured virgin rubber material).

[0040] In another aspect, the present disclosure is directed to machines (e.g., for use in preparing recycled rubber materials) comprising an abrading wheel, wherein the abrading wheel comprises steel (e.g., A36 steel) and an abrasive having a grit of at most about 200, at most about 100, at most about 80, at most about 60, at most about 50, at most about 40, or at most about 20.

[0041] In some embodiments, abrasives comprise one or more members selected from the group consisting of diamond, aluminum oxide, corundum, zirconium, ceramics, silicon carbide, and any combination thereof.

[0042] In some embodiments, machines further comprise a rubber trim feed system for feeding rubber trim to an abrading wheel.

[0043] In some embodiments, rubber trim feed systems feed rubber trim to an abrading wheel at an angle within a range of about 15°-75°, within a range of about 20°-70°, within a range of about 25°-65°, within a range of about 30°-60° within a range of about 35°- 55°, or within a range of about 40°-50°.

[0044] In some embodiments, rubber trim feed systems feed rubber trim to an abrading wheel at an angle within a range of about 30° to about 45°.

[0045] In some embodiments, machines comprise a gap between an abrading wheel and rubber trim feed system, the gap being within a range of about 0.001 inches and about 0.01 inches, or about 0.003 inches and about 0.008 inches. Page 7 of 60 12187367v1Attorney Docket No.: 2006702-0042

[0046] In some embodiments, machines comprise a system for maintaining a gap between an abrading wheel and a rubber trim feed system.

[0047] In some embodiments, machines comprise a system configured to cool and / or heat an abrading wheel (e.g., to prevent thermal expansion / contraction).

[0048] In some embodiments, abrading wheels comprise a water jacketing system.

[0049] In some embodiments, water jacketing systems are configured to limit (or prevent) thermal expansion and / or contraction of the abrading wheel.

[0050] In some embodiments, water jacketing systems are configured to circulate a fluid (e.g., water) through an abrading wheel (e.g., an outer portion of an abrading wheel).

[0051] In some embodiments, systems configured to cool / and or heat abrading wheels are configured to cool abrading surfaces of abrading wheels.

[0052] In some embodiments, rubber trim comprises natural rubber and / or at least one synthetic rubber.

[0053] In some embodiments, at least one synthetic rubber comprises one or more members selected from the group consisting of styrene-butadiene rubber (SBR), nitrile rubber (e.g., acrylonitrile butadiene rubber), ethylene propylene diene monomer rubber (EPDM), synthetic polyisoprene (e.g., cis-1,4-polyisoprene), chloroprene rubber, butyl rubber, butadiene rubber, ethylene propylene rubber, fluoro-rubber, silicone rubber, thermoplastic elastomer.

[0054] In some embodiments, abrading wheels are configured to rotate at a speed of at least about 500 rpm, at least about 1000 rpm, at least about 1500 rpm, at least about 2000 rpm, at least about 2500 rpm, at least about 3000 rpm, at least about 3500 rpm, at least about 4000 rpm, at least about 4500 rpm, or at least about 5000 rpm.

[0055] In some embodiments, abrading wheels have a diameter of between about 5 inches and about 35 inches and / or a width of between about 1 inch and about 6 inches.

[0056] In some embodiments, machines further comprise a drive belt for driving abrading wheels.

[0057] In some embodiments, after rubber trim is fed through machines, rubber trim is converted into a composition of micronized cured rubber particles.

[0058] In some embodiments, at least 90% of micronized cured rubber particles have a particle size less than about 5600 µm, less than about 4750 µm, less than about 4000 µm, less than about 3350 µm, less than about 3170 µm, less than about 2800 µm, less than about Page 8 of 60 12187367v1Attorney Docket No.: 2006702-0042 2360 µm, less than about 2000 µm, less than about 1700 µm, less than about 1400 µm, less than about 1180 µm, less than about 1000 µm, less than about 850 µm, less than about 710 µm, less than about 600 µm, less than about 500 µm, less than about 425 µm, less than about 355 µm, less than about 300 µm, or less than about 250 µm.

[0059] In some embodiments, abrading wheels, when fed rubber trim, granulate previously cured rubber materials at a rate within a range of about 0.5 ft / min to about 20 ft / min, about 1 ft / min to about 15 ft / min, about 3 ft / min to about 10 ft / min, or about 6 ft / min to about 7 ft / min.

[0060] In another aspect, the present disclosure is directed to recycled rubber compositions comprising an uncured rubber component (e.g., an uncured virgin rubber component) and a previously cured rubber component, wherein the previously cured rubber component comprises micronized cured rubber particles (e.g., rubber crumb) derived from a previously cured rubber material, and the previously cured rubber component is at least about 1 wt%, at least about 5 wt%, at least about 10 wt%, at least about 15 wt%, at least about 20 wt%, at least about 25 wt%, at least about 30 wt%, at least about 35 wt%, at least about 40 wt%, at least about 45 wt%, or at least about 50 wt% of the rubber composition.

[0061] In some embodiments, at least 90% of micronized cured rubber particles of previously cured rubber components have a particle size less than about 5600 µm, less than about 4750 µm, less than about 4000 µm, less than about 3350 µm, less than about 3170 µm, less than about 2800 µm, less than about 2360 µm, less than about 2000 µm, less than about 1700 µm, less than about 1400 µm, less than about 1180 µm, less than about 1000 µm, less than about 850 µm, less than about 710 µm, less than about 600 µm, less than about 500 µm, less than about 425 µm, less than about 355 µm, less than about 300 µm, or less than about 250 µm.

[0062] In some embodiments, at least 99% of micronized cured rubber particles have a particle size of about 1000 µm or less, about 965 µm or less, about 950 µm or less, about 880 µm or less, about 800 µm or less, about 743 µm or less, about 697 µm or less, about 558 µm or less.

[0063] In some embodiments, at least 50% of micronized cured rubber particles have a particle size of about 350 µm or less, about 325 µm or less, about 305 µm or less, about 300 µm or less, about 242 µm or less, about 159 µm or less. Page 9 of 60 12187367v1Attorney Docket No.: 2006702-0042

[0064] In some embodiments, the SMD of micronized cured rubber particles is about 500 µm or less, about 400 µm or less, about 300 µm or less, about 250 µm or less, about 236 µm or less, about 180 µm or less, about 165 µm, about 132 µm or less.

[0065] In some embodiments, uncured rubber components comprise natural rubber and / or at least one synthetic rubber. In some embodiments, at least one synthetic rubber comprises one or more members selected from the group consisting of: styrene-butadiene rubber (SBR), nitrile rubber (e.g., acrylonitrile butadiene rubber), ethylene propylene diene monomer rubber (EPDM), synthetic polyisoprene (e.g., cis-1,4-polyisoprene), chloroprene rubber, butyl rubber, butadiene rubber, ethylene propylene rubber, fluoro-rubber, silicone rubber, and thermoplastic elastomer.

[0066] In some embodiments, previously cured rubber components comprise natural rubber and / or at least one synthetic rubber. In some embodiments, at least one synthetic rubber comprises one or more members selected from the group consisting of: styrene- butadiene rubber (SBR), nitrile rubber (e.g., acrylonitrile butadiene rubber), ethylene propylene diene monomer rubber (EPDM), synthetic polyisoprene (e.g., cis-1,4- polyisoprene), chloroprene rubber, butyl rubber, butadiene rubber, ethylene propylene rubber, fluoro-rubber, silicone rubber, and thermoplastic elastomer.

[0067] In some embodiments, recycled rubber compositions further comprise one or more additional components selected from the group consisting of: clay, silica, carbon-black, aromatic process oil, zinc oxide, antioxidant, additives, sulfur, accelerators, calcium carbonate, and naphthenic process oil.

[0068] In some embodiments, micronized cured rubber particles of recycled rubber compositions have a surface comprising asperities (e.g., have a porous surface, e.g., have a surface roughness capable of being characterized by microscopy, e.g., optical microscopy, scanning electron microscopy).

[0069] In some embodiments, surfaces comprising asperities are characterized by determining a surface area (e.g., a specific surface area) using a gas adsorption analysis (e.g., Brunauer-Emmett-Teller (BET) surface area analysis).

[0070] In some embodiments, recycled rubber compositions are substantially free of rubber de-linking accelerators (e.g., de-vulcanization chemicals, e.g., de-linking chemicals). Page 10 of 60 12187367v1Attorney Docket No.: 2006702-0042

[0071] In another aspect, the present disclosure is directed to improvements comprising using disclosed recycled rubber compositions in a method of manufacturing an end product from a rubber material.

[0072] In another aspect, the present disclosure is directed to improvements comprising incorporating micronized cured rubber particles into a recycled rubber composition. In some embodiments, incorporating is by methods disclosed herein. BRIEF DESCRIPTION OF THE DRAWING

[0073] FIG.1 shows an exemplary rubber production process (100). The exemplary process (100) includes the steps of mixing together materials of virgin rubber materials (110), calendering or extruding the rubber formulation into sheets (i.e., “preforms”) (115); heat molding the preforms (i.e., vulcanization and molding) (120), sanding and trimming the cured rubber (125), applying a surface finishing (e.g., a surface treatment) (130), and inspecting / packaging the material (135), producing a finished product (240).

[0074] FIG.2 shows an exemplary production process (200) for making recycled rubber materials. The exemplary process includes the steps of abrading a cured rubber material to form micronized rubber particles (i.e., micronisation) and, optionally, de- vulcanizing the micronized rubber particles, mixing (210) together raw materials (e.g., virgin rubber materials) (205) with recycled micronized rubber particles (e.g., as produced in step 255), calendaring the rubber formulation into sheets (i.e., “preforms”) (215); heat molding the preforms (i.e., vulcanization and molding), sanding and trimming the cured rubber (225), applying a surface finishing (e.g., a surface coating) (230), and inspecting / packaging the material (235), producing a finished product (240). The process (200) optionally includes steps of cutting a finished roll of rubber into trims (e.g., using a slitter) (250). The trims may then be micronized into powder for recycling (255).

[0075] FIG.3 shows an illustrative embodiment of a rubber recycling system in accordance with the present disclosure, used to process and granulate rubber materials. The non-limiting, exemplified system contains an abrading wheel and the rubber trim is presented to the abrading wheel at a constant pressure and at a 45° angle. Panel A provides a top view of an exemplary rubber recycling system unit. Panel B provides a schematic of an exemplary rubber recycling system. Panel C provides a close-up photograph of a trim feed system, Page 11 of 60 12187367v1Attorney Docket No.: 2006702-0042 which may be included in embodiments in accordance with the present disclosure. Panel D shows an illustrative embodiment of a cutaway of an abrading wheel.

[0076] FIG.4 shows micronized rubber particles of various types of rubber trims tranformed with a protype unit. Panels A-C show via optical microscopy SBR rubber powder (SBR Formula 1) micronized using abrasives having varying grits, in accordance with the present disclosure. Panels D-F show via optical microscopy EPDM rubber powder (EPDM Formula 1) micronized using abrasives having varying grits, in accordance with the present disclosure. Panels G and H show via optical microscopy natural rubber (NR) powder (NR Formula 1) micronized using abrasives having varying grits, in accordance with the present disclosure.

[0077] FIG.5 shows via optical microscopy images of micronized rubber particles of various types of rubber materials powdered with Exemplary Unit B using a 100 grit abrading wheel. Panel A shows micronized SBR rubber trim powder (SBR Formula 1). Panel B shows micronized EPDM rubber trim powder (EPDM Formula 1). Panel C shows micronized NR rubber trim powder (NR Formula 1).

[0078] FIG.6 shows SEM images of micronized rubber SBR powder generated using processes and devices as described and exemplified herein. Panels A-C show SEM micronized rubber generated using a conventional Condux® grinding process at 200X (Panel A), 1000X (Panel B), and 5000X (Panel C) magnifications. Panels D-F show SEM micronized rubber generated using a 100 grit abrasive wheel on a Exemplary Unit Bat 200X (Panel D), 1000X (Panel E), and 5000X (Panel F) magnifications. Panels D-F show SEM micronized rubber generated using a 20 / 30 grit abrasive wheel on Exemplary Unit B at 200X (Panel G), 1000X (Panel H), and 5000X (Panel I) magnifications.

[0079] FIG.7 shows particle size distributions of micronized SBR powders generated using processes and devices as described and exemplified herein. Panel A shows frequency of particle distribution and a cumulative distribution function of particles for powder generated using a conventional Condux® grinding process. Panel B shows frequency of particle distribution and a cumulative distribution function of particles for powder generated using an exemplary unit with a 100 grit abrasive wheel. Panel C shows frequency of particle distribution and a cumulative distribution function of particles for powder generated using an exemplary unit with a 20 / 30 grit abrasive wheel. Particle size was measured using laser diffraction with dynamic imaging. Page 12 of 60 12187367v1Attorney Docket No.: 2006702-0042

[0080] FIG.8 shows SEM images and size distribution of a natural rubber powder generated using processes and devices described herein. An abrasive wheel with 20 / 30 grit powders was used to generate natural rubber (NR) powder. Panel A shows a 200x SEM image of a natural rubber powder. Panel B shows a 1000x SEM image of natural rubber powder. Panel C shows a 5000x SEM image of a natural rubber powder. Panel D shows particle size distribution (cumulative distribution and frequency distribution) of the natural rubber powder. DEFINITIONS

[0081] A or An: The articles “a” and “an” are used herein to refer to one or to more than one (i.e., to at least one) of the grammatical object of the article. By way of example, “an element” refers to one element or more than one element.

[0082] Approximately: As used herein, the term “approximately” or “about,” as applied to one or more values of interest, refers to a value that is similar to a stated reference value. In certain embodiments, the term “approximately” or “about” refers to a range of values that fall within 20%, 19%, 18%, 17%, 16%, 15%, 14%, 13%, 12%, 11%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, or less in either direction (greater than or less than) of the stated reference value unless otherwise stated or otherwise evident from the context (except where such number would exceed 100% of a possible value).

[0083] Agent: As used herein, the term “agent”, may refer to a physical entity or phenomenon. In some embodiments, an agent may be characterized by a particular feature and / or effect. In some embodiments, an agent may be a compound, molecule, or entity of any chemical class including, for example, a small molecule, polypeptide, nucleic acid, saccharide, lipid, metal, or a combination or complex thereof. In some embodiments, the term “agent” may refer to a compound, molecule, or entity that comprises a polymer. In some embodiments, the term may refer to a compound or entity that comprises one or more polymeric moieties. In some embodiments, the term “agent” may refer to a compound, molecule, or entity that is substantially free of a particular polymer or polymeric moiety. In some embodiments, the term may refer to a compound, molecule, or entity that lacks or is substantially free of any polymer or polymeric moiety.

[0084] Comparable: As used herein, the term “comparable” refers to two or more agents, entities, situations, sets of conditions, etc., that may not be identical to one another but Page 13 of 60 12187367v1Attorney Docket No.: 2006702-0042 that are sufficiently similar to permit comparison there between so that one skilled in the art will appreciate that conclusions may reasonably be drawn based on differences or similarities observed. In some embodiments, comparable sets of conditions, circumstances, individuals, or populations are characterized by a plurality of substantially identical features and one or a small number of varied features. Those of ordinary skill in the art will understand, in context, what degree of identity is required in any given circumstance for two or more such agents, entities, situations, sets of conditions, etc to be considered comparable. For example, those of ordinary skill in the art will appreciate that sets of circumstances, individuals, or populations are comparable to one another when characterized by a sufficient number and type of substantially identical features to warrant a reasonable conclusion that differences in results obtained or phenomena observed under or with different sets of circumstances, individuals, or populations are caused by or indicative of the variation in those features that are varied.

[0085] Composition: Those skilled in the art will appreciate that the term “composition” may be used to refer to a discrete physical entity that comprises one or more specified components. In general, unless otherwise specified, a composition may be of any form – e.g., gas, gel, liquid, solid, etc.

[0086] Comprising: A composition or method described herein as "comprising" one or more named elements or steps is open-ended, meaning that the named elements or steps are essential, but other elements or steps may be added within the scope of the composition or method. To avoid prolixity, it is also understood that any composition or method described as "comprising" (or which "comprises") one or more named elements or steps also describes the corresponding, more limited composition or method "consisting essentially of" (or which "consists essentially of") the same named elements or steps, meaning that the composition or method includes the named essential elements or steps and may also include additional elements or steps that do not materially affect the basic and novel characteristic(s) of the composition or method. It is also understood that any composition or method described herein as "comprising" or "consisting essentially of" one or more named elements or steps also describes the corresponding, more limited, and closed-ended composition or method "consisting of" (or "consists of") the named elements or steps to the exclusion of any other unnamed element or step. In any composition or method disclosed herein, known or disclosed equivalents of any named essential element or step may be substituted for that element or step. Page 14 of 60 12187367v1Attorney Docket No.: 2006702-0042

[0087] Conjugated: As used herein, the terms “conjugated,” “linked,” “attached,” and “associated with,” when used with respect to two or more moieties, means that the moieties are physically associated or connected with one another, either directly or via one or more additional moieties that serves as a linking agent, to form a structure that is sufficiently stable so that the moieties remain physically associated under the conditions in which structure is used. Typically the moieties are attached either by one or more covalent bonds or by a mechanism that involves specific binding. Alternately, a sufficient number of weaker interactions can provide sufficient additional stability to remain physically associated.

[0088] Cured: As used herein, the term “cured” refers to a description of a material and / or composition (e.g., a rubber material and / or composition) that has undergone any of a variety of curing processes to confer, improve, or extend elastic properties of the material and / or composition. In a non-limiting example, an exemplary curing process may be vulcanization, wherein elastic properties are conferred, improved, or extended to a material and / or composition via a change in the chemical structure (e.g., crosslinking).

[0089] Elastomer: As used herein, the term “elastomer” refers to any of a variety of polymers or combinations of polymers which can be characterized as being elastic and / or having elasticity. As used herein, the term “elastomer” may be used interchangeably with the term “rubber”.

[0090] “Improve,” “increase”, “inhibit” or “reduce”: As used herein, the terms “improve”, “increase”, “inhibit’, “reduce”, or grammatical equivalents thereof, indicate values that are relative to a baseline or other reference measurement. In some embodiments, an appropriate reference measurement may be or comprise a measurement in a particular system under otherwise comparable conditions absent presence of (e.g., prior to and / or after) a particular agent or treatment, or in presence of an appropriate comparable reference agent. In some embodiments, an appropriate reference measurement may be or comprise a measurement in comparable system known or expected to respond in a particular way, in presence of the relevant agent or treatment.

[0091] Hydrophilic: As used herein, the term “hydrophilic” and / or “polar” refers to a tendency to mix with, or dissolve easily in, water.

[0092] Hydrophobic: As used herein, the term “hydrophobic” and / or “non-polar”, refers to a tendency to repel, not combine with, or an inability to dissolve easily in, water. Page 15 of 60 12187367v1Attorney Docket No.: 2006702-0042

[0093] Pure: As used herein, an agent or entity is “pure” if it is substantially free of other components. For example, a preparation that contains more than about 90% of a particular agent or entity is typically considered to be a pure preparation. In some embodiments, an agent or entity is at least 91%, at least 92%, at least 93%, at least 94%, at least 95%, at least 96%, at least 97%, at least 98%, or at least 99% pure.

[0094] Recycled: As used herein, the term “recycled” refers to a description of a material, and / or composition therein which comprises at least one component which has been previously processed, manufactured, and / or used.

[0095] Reference: As used herein describes a standard or control relative to which a comparison is performed. For example, in some embodiments, an agent, animal, individual, population, sample, sequence or value of interest is compared with a reference or control agent, animal, individual, population, sample, sequence or value. In some embodiments, a reference or control is tested and / or determined substantially simultaneously with the testing or determination of interest. In some embodiments, a reference or control is a historical reference or control, optionally embodied in a tangible medium. Typically, as would be understood by those skilled in the art, a reference or control is determined or characterized under comparable conditions or circumstances to those under assessment. Those skilled in the art will appreciate when sufficient similarities are present to justify reliance on and / or comparison to a particular possible reference or control.

[0096] Solution: As used herein, the term “solution” broadly refers to a homogeneous mixture composed of one phase. Typically, a solution comprises a solute or solutes dissolved in a solvent or solvents. It is characterized in that the properties of the mixture (such as concentration, temperature, and density) can be uniformly distributed through the volume.

[0097] Substantially: As used herein, the term “substantially” refers to the qualitative condition of exhibiting total or near-total extent or degree of a characteristic or property of interest. One of ordinary skill in the biological arts will understand that biological and chemical phenomena rarely, if ever, go to completion and / or proceed to completeness or achieve or avoid an absolute result. The term “substantially” is therefore used herein to capture the potential lack of completeness inherent in many biological and chemical phenomena. Page 16 of 60 12187367v1Attorney Docket No.: 2006702-0042

[0098] Substantially free of: As used herein, the phrase “substantially free of”, and grammatic equivalents, refer to the qualitative condition of exhibiting absence or total, approximately or near-total absence. One of ordinary skill in the art will appreciate that achieving an absence or near total absence includes, within a range of less than 15 %, e.g., less than 10%, less than 5%, or less than 1%.

[0099] Uncured: As used herein, the term “uncured” refers to a material and / or composition (e.g., an elastomer material and / or composition) which has not undergone or has yet to undergo any of a variety of curing processes to confer, improve, or extend elastic properties to the material and / or composition.

[0100] Virgin: As used herein, the term “virgin” refers to a description of a material and / or composition which has been subjected to processing only for its initial production and does not include components which may be characterized as “recycled”. DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS Rubber Materials and Recycling of the Same

[0101] The present disclosure provides among other things, rubber materials, methods and systems for preparing the same. Implementations of disclosed embodiments of the present disclosure provide for recycling rubber materials, for example to produce recycled rubber materials. In many embodiments, recycled rubber materials may be prepared from previously cured rubber materials utilizing disclosed methods and / or systems. As presented herein, previously cured rubber materials include any of a variety of rubber materials which have previously been processed, manufactured, and / or used. Previously cured rubber materials may be or comprise any of a variety of rubber products which are to be recycled and / or included in a recycled rubber material and / or composition. By way of non-limiting example, previously cured rubber materials may be scrap rubber materials produced during manufacture of rubber products, such as rubber trims. As another non-limiting example, previously cured rubber materials may be worn out and / or used rubber products, such as used rubber tires.

[0102] In accordance with various embodiments of the present disclosure, any of a variety of rubber materials may be utilized to produce recycled rubber materials and / or recycled rubber compositions. For example, in some embodiments, exemplary rubber materials may comprise or be naturally-derived rubber materials. Additionally or Page 17 of 60 12187367v1Attorney Docket No.: 2006702-0042 alternatively, exemplary rubber materials may comprise or be synthetically-derived rubber materials. Further, in some embodiments, rubber materials may comprise or be combinations of naturally-derived rubber materials and synthetically-derived rubber materials.

[0103] In some embodiments, naturally-derived rubber materials may be natural rubber. By way of non-limiting example, natural rubber may be derived from latex harvested from any of a variety of latex-producing plants and / or trees, for example, rubber trees.

[0104] In some embodiments, synthetically-derived rubber materials may be any of a variety of synthetic rubbers. By way of non-limiting example a synthetic rubber may be derived from petrochemical sources. For example, a synthetic rubber may be one or more of styrene-butadiene rubber (SBR), nitrile rubber (e.g., acrylonitrile butadiene rubber), ethylene propylene diene monomer rubber (EPDM), synthetic polyisoprene (e.g., cis-1,4- polyisoprene), chloroprene rubber, butyl rubber (e.g., chlorobutyl rubber), butadiene rubber, ethylene propylene rubber, fluoro-rubber, silicone rubber, any of a variety of thermoplastic elastomers, or any combination thereof.

[0105] In some embodiments, disclosed recycled rubber materials and / or compositions comprise an uncured rubber component and a previously cured rubber component. In some embodiments, an uncured rubber component may be an uncured virgin rubber component. For example, an uncured virgin rubber component may be any uncured virgin rubber material and / or composition disclosed herein. In some embodiments, a previously cured rubber component may be or comprise any previously cured rubber material and / or compositions disclosed herein. For example, a previously cured rubber component may be or comprise disclosed micronized rubber compositions.

[0106] In some embodiments, disclosed recycled rubber materials and / or compositions comprise previously cured rubber components in a proportion of at least about 1 wt%, at least about 5 wt%, at least about 10 wt%, at least about 15 wt%, at least about 20 wt%, at least about 25 wt%, at least about 30 wt%, at least about 35 wt%, at least about 40 wt%, at least about 45 wt%, or at least about 50 wt% of the rubber composition.

[0107] In some embodiments, disclosed recycled rubber materials and / or compositions comprise additional components. For example, in some embodiments, additional components may be least one of fillers, pigments, process oils, curing system, activators, additives, antioxidants, reinforcing agents (e.g., carbon-black, e.g., silica), or any combination thereof. Page 18 of 60 12187367v1Attorney Docket No.: 2006702-0042

[0108] In some embodiments, disclosed recycled rubber materials and / or compositions comprise one or more fillers. In some embodiments, a filler may be or comprise clay and / or calcium carbonate.

[0109] In some embodiments, disclosed recycled rubber materials and / or compositions comprise one or more reinforcing agents. In accordance with various embodiments, any of a variety of reinforcing agents may be used. By way of non-limiting example, in some embodiments, a reinforcing agent may be or comprise carbon-black. As another non-limiting example, in some embodiments, a reinforcing agent may be or comprise silica.

[0110] In some embodiments, disclosed recycled rubber materials and / or compositions comprise one or more process oils. In some embodiments, a process oil may be or comprise aromatic process oil and / or naphthenic process oil.

[0111] As appreciated by ordinary skill in the art, vulcanization is a chemical process for converting rubber or related polymers into more durable material using sulfur or other curing systems (e.g., cure packages). An important ingredient for recycled rubber materials is a curing system that causes interlinking reactions to take place when the material is cured to prepare its recycled rubber product. In general a curing system (e.g., a cure package) includes, but is not limited to, sulfur systems, peroxides, urethane crosslinkers, metallic oxides, etc..

[0112] Many traditional rubber materials / products employ a sulfur-based curing system (e.g., a cure package). A sulfur-based curing system, in some embodiments, contains sulfur and one or more “accelerators” (e.g., sulfenamides, thiurams, or thiazoles), which make the sulfur interlinking reaction occur faster and more efficiently. Other ingredients that play an important role in vulcanization chemistry are known as “activators,” commonly zinc oxide and stearic acid. Such activators can react together and with an accelerator to form a zinc sulfur complex, which in turn is the key intermediary in adding sulfur to a diene elastomer and creating sulfur interlinks. Micronized Rubber Compositions

[0113] In some embodiments, micronized rubber compositions comprise micronized cured rubber particles. In some embodiments, at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, or at least about 99% of micronized cured Page 19 of 60 12187367v1Attorney Docket No.: 2006702-0042 rubber particles of micronized cured rubber particle compositions have a particle size (e.g., a diameter) less than a threshold value. In some embodiments, a threshold value may be about 5600 µm, about 4750 µm, about 4000 µm, about 3350 µm, about 3170 µm, about 2800 µm, about 2360 µm, about 2000 µm, about 1700 µm, about 1400 µm, about 1180 µm, about 1000 µm, about 850 µm, about 710 µm, about 600 µm, about 500 µm, about 425 µm, about 355 µm, about 300 µm, or about 250 µm. As a non-limiting example, at least about 90% of micronized cured rubber particles of a micronized cured rubber particle composition may have a particle size less than about 5600 µm. In some embodiments, at least 99% of micronized cured rubber particles of a micronized cured rubber particle composition have a particle size of about 1000 µm or less, about 965 µm or less, about 950 µm or less, about 880 µm or less, about 800 µm or less, about 743 µm or less, about 697 µm or less, about 558 µm or less.

[0114] In some embodiments, at least 50% of micronized cured rubber particles of a micronized cured rubber particle composition have a particle size of about 350 µm or less, about 325 µm or less, about 305 µm or less, about 300 µm or less, about 242 µm or less, about 159 µm or less.

[0115] In some embodiments, the Sauter mean diameter (SMD) of micronized cured rubber particles is about 500 µm or less, about 400 µm or less, about 300 µm or less, about 250 µm or less, about 236 µm or less, about 180 µm or less, about 165 µm, about 132 µm or less.

[0116] In some embodiments, the Sauter mean diameter (SMD) is used to evaluate particles. In some embodiments, micronized cured rubber particles have a Sauter mean diameter (SMD) of about 50 µm, about 100 µm, about 150 µm, about 160 µm, about 200 µm, about 250 µm, about 300 µm, about 350 µm, about 400 µm, about 500 µm, about 550 µm, about 600 µm, about 600 µm, about 620 µm, about 650 µm, about 700 µm, about 750 µm, about 800 µm, about 850 µm, about 900 µm, about 1000 µm. In some embodiments, the SMD of micronized cured rubber particles is about 500 µm or less, about 400 µm or less, about 300 µm or less, about 250 µm or less, about 236 µm or less, about 180 µm or less, about 165 µm, about 132 µm or less. In some embodiments, the SMD is from about 500 µm to about 100 µm.

[0117] In some embodiments, micronized cured rubber particles have a mean or average diameter from about 50 µm to about 1000 µm, from about 100 µm to about 400 µm, Page 20 of 60 12187367v1Attorney Docket No.: 2006702-0042 from about 100 µm to about 200 µm, from about 150 µm to about 200 µm, from about 600 µm to about 650 µm, from about 250 µm to about 300 µm, from about 750 µm to about 800 µm.

[0118] Any of a variety of methods, techniques, or protocols may be used to quantify and / or characterize particle sizes and / or particle size distributions of disclosed micronized cured rubber particle compositions. For example, in some embodiments, exemplary micronized cured rubber particle sizes and / or particle size distributions may be characterized by sieve analysis, e.g., in accordance with ASTM D5644. Additionally or alternatively, in some embodiments, micronized cured rubber particle sizes and / or particle size distributions may be characterized utilizing particle size analyzers, such as laser diffraction particle size analyzers (e.g. a Malvern Mastersizer, a QICPIC® system from Sympatec).

[0119] In some embodiments, micronized rubber compositions are included in recycled rubber materials and / or compositions in a proportion of at least about 5 wt%, at least about 10 wt%, at least about 15 wt%, at least about 20 wt%, at least about 25 wt%, at least about 30 wt%, at least about 40 wt%, or at least about 50 wt%.

[0120] In some embodiments, micronized cured rubber particles have surfaces comprising asperities. For example, in some embodiments, micronized rubber particles have surfaces which may be characterized as porous and / or as having surface irregularities. In some embodiments, surfaces of micronized cured rubber particles having asperities are capable of being characterized and / or confirmed by optical microscopy, for example, as presented in FIG.5 and FIG.6. Additionally or alternatively, in some embodiments, surface roughness may be characterized utilizing any of a variety of surface area analyses, such as gas adsorption analysis. For example, in some embodiments, Brunauer-Emmett-Teller (BET) surface area analysis may be utilized to determine particle surface roughness or irregularities of micronized cured rubber particles of the present disclosure. Methods for Preparing Recycled Rubber Materials 1. Granulating

[0121] In some embodiments, disclosed methods for producing recycled rubber materials comprise granulating rubber materials to generate micronized rubber particle compositions. As described herein, granulating rubber materials typically refers to any physical process by which larger materials (e.g., rubber trims) are broken down into smaller Page 21 of 60 12187367v1Attorney Docket No.: 2006702-0042 particles. In some embodiments described herein, particles having been granulated to a size (e.g., diameter) of about 10000 µm or less are referred to as micronized particles. In some embodiments, micronized particles (e.g., as generated using an abrading wheel) have a size of about 1000 µm or less. In accordance with various embodiments of the present disclosure, any of a variety of methods and / or systems may be utilized for granulating and micronizing of rubber materials. By way of non-limiting example, granulating and micronizing may be or comprise abrading rubber materials utilizing an abrading wheel. Alternatively, in some embodiments, granulating and micronizing may be or comprise abrading rubber materials utilizing sand paper (e.g., utilizing a belt sander).

[0122] In accordance with various embodiments of the present disclosure, any of a variety of abrading wheels may be utilized for granulating and micronizing. For example, in some embodiments, exemplary abrading wheels comprise steel, such as A36 steel, or another material or combination of materials of similar hardness.

[0123] In some embodiments, exemplary abrading wheels comprise an abrasive. Any of a variety of abrasives may be utilized for abrading. In many embodiments, abrasives can be any of a variety of natural and / or synthetic material which is characterized as having a high hardness. For example, abrasives may have a value equal to or greater than 7 based on the Mohs Hardness Scale. Exemplary abrasives include, but are not limited to, diamond, aluminum oxide, corundum, zirconium, ceramics, silicon carbide, or any combination thereof. By way of non-limiting example, in some embodiments, an abrasive comprises diamond (e.g., diamond electroplated onto a steel wheel to make an abrading wheel, e.g., diamond vacuum brazed onto a steel wheel to make an abrading wheel, e.g., diamond included in the bulk of the abrading wheel), or another abrasive or combination of abrasives of similar hardness and / or grit.

[0124] In some embodiments, exemplary abrasives have a grit of at most about 200, at most about 100, at most about 80, at most about 60, at most about 50, at most about 40, or at most about 20. Without wishing to be bound by any particular theory, grit size may be a parameter that is useful in achieving a particular particle size and / or particle size distribution and / or micronized powder output rate.

[0125] In some embodiments, abrading comprises presenting rubber materials to an abrading component (e.g., an abrading wheel) to convert rubber materials to micronized rubber particle compositions of the present disclosure. In certain embodiments, an abrading Page 22 of 60 12187367v1Attorney Docket No.: 2006702-0042 component may include, for example, one or more abrading wheels. In accordance with various embodiments of the present disclosure, presenting rubber materials may be performed by any of a variety of methods and / or systems. By way of non-limiting example, presenting rubber materials may be or comprise feeding rubber materials utilizing rubber feed systems which present rubber materials to an abrading component at an angle useful for producing micronized rubber particles of the present disclosure. In certain embodiments, a rubber feed system is configured to provide one or more rubber trims to an abrading component (e.g., an abrading wheel). In certain embodiments, two rubber trims are provided side-by-side to an abrading component. In certain embodiments, two rubber trims are stacked on top of one another and provided to an abrading component.

[0126] In some embodiments, presenting rubber materials comprises presenting exemplary rubber materials to an abrading component at an angle within a range of about 15°-75°, within a range of about 20°-70°, within a range of about 25°-65°, within a range of about 30°-60° within a range of about 35°-55°, or within a range of about 40°-50°. For example, abrading comprises presenting rubber materials to an abrading wheel at an angle within a range of about 30° to about 45°.

[0127] In some embodiments, a gap is present between rubber feed systems and one or more abrading wheels (e.g., two, three, four, or more). For example, in some embodiments, a gap between a rubber feed system and an abrading wheel is within a range of about 0.001 inches and 0.01 inches. In some embodiments, a gap between a rubber feed system and an abrading wheels is within a range of about 0.003 inches and 0.008 inches. In some embodiments, a gap is maintained through use of one or more systems to monitor and / or control a gap between an abrading wheel and a rubber feed system. In some embodiments, systems used to monitor and / or control a gap between an abrading wheel and rubber feed system control a temperature of an abrading wheel or a portion of an abrading wheel (e.g., an abrading surface).

[0128] In some embodiments, a plurality of abrading wheels are used to generate micronized rubber particle compositions. In some embodiments, a plurality of (e.g., two, three, or more) abrading wheels are arranged side-by-side such that a rubber feed system provides material to both abrading wheels. Other configurations of abrading wheels can be used and implemented to meet needs of processes described herein. Page 23 of 60 12187367v1Attorney Docket No.: 2006702-0042

[0129] In some embodiments, abrading wheels may have a diameter of between about 5 inches and about 35 inches. Further, in some embodiments, an abrading wheel may have a width of between about 1 inch and about 6 inches. In some embodiments, an abrading wheel may have a width between about 1 inch and about 8 inches. In some embodiments, multiple abrading wheels may be placed side-by-side so that wheels having greater widths may be utilized in accordance with various embodiments of the present disclosure.

[0130] In some embodiments, abrading wheels may heat up during granulation and micronization processes. Due to thermal expansion, abrading wheels that are heated during granulation or micronization processes may become larger in diameter with higher temperature. Therefore, thermal expansion can cause changes in device parameters such as, for example, a gap between a rubber feed system and an abrading wheel, which could alter material produced by micronization. Accordingly, in some embodiments, the temperature of an abrading wheel can be controlled to prevent and / or thermal expansion effects. In some embodiments, a system is configured to cool and / or heat an abrading wheel (e.g., to prevent thermal expansion / contraction). In some embodiments, an abrading wheel is heated and / or cooled through the use of a water jacketing system. In the present embodiments, a water jacketing system is or comprises a system to circulate a liquid (e.g., water) in order to cool an abrading wheel. In some embodiments, the outer surface of an abrading wheel is cooled through use of a water jacketing system. In some embodiments, a surface of the abrading wheel is cooled and / or heated during abrading to maintain a temperature within 20°C, within 10°C, within 5°C, within 4°C, within 2°C of an initial or pre-defined temperature (e.g., a set temperature). Maintaining control over temperature prevents significant thermal expansion and / or contraction of an abrading wheel. In certain embodiments, an abrading surface is the surface which contacts rubber being granulated or micronized.

[0131] For example, FIG.3, panel D shows an illustrative embodiment of a cutaway of an abrading wheel with a water jacketing system. A fluid is circulated through a serpentine path of tubing within the outer perimeter of the abrading wheel. The outer abrasive surface of the abrading wheel is cooled as water is flowed through the system. In the embodiment shown in FIG.3, panel D, water does not come into direct contact with materials being processed (e.g., micronized rubber particles).

[0132] In some embodiments, abrading wheels are operated by a drive belt to achieve operating speeds appropriate for certain embodiments. Additionally, in some instances, brake Page 24 of 60 12187367v1Attorney Docket No.: 2006702-0042 calipers control operating speeds. In some embodiments, exemplary abrading wheels operate at a speed of at least about 500 rpm, at least about 1000 rpm, at least about 1500 rpm, at least about 2000 rpm, at least about 2500 rpm, at least about 3000 rpm, at least about 3500 rpm, at least about 4000 rpm, at least about 4500 rpm, or at least about 5000 rpm. Without wishing to be bound by any particular theory, operating speeds of abrading wheels may be a parameter that is useful in achieving a particular particle size and / or particle size distribution and / or micronized powder output rate.

[0133] Without wishing to be bound by any particular theory, micronized powder output rates may be also depend on other parameters. By way of non-limiting example, exemplary parameters include dimensions of rubber trims (e.g., thickness and / or width). Thus, in some embodiments, granulating and micronizing may be characterized by a rate at by which exemplary rubber trim is processed in accordance with embodiments of the present disclosure. By way of non-limiting example, a rate may be in ft / min. Accordingly in some embodiments, rubber trims are granulated or micronized at a rate within a range of about 0.5 ft / min to about 20 ft / min, about 1 ft / min to about 15 ft / min, about 3ft / min to about 10 ft / min, or about 6 ft / min to about 7 ft / min.

[0134] Without wishing to be bound by any theory, such parameters of the abrading wheel (e.g., feed angle, diameter, thickness, speed, temperature) may be provided such that the force applied to the cured rubber material results in a micronized rubber material of sufficiently small particle size and output rate. 2. Formulating / Mixing

[0135] In some embodiments, micronized cured rubber particle compositions described herein (i.e., recycled rubber compositions) are mixed with uncured rubber compositions (e.g., uncured virgin rubber compositions) during production of exemplary recycled rubber compositions and / or materials. For example, in some embodiments, mixing comprises mixing micronized cured rubber particle compositions, uncured rubber compositions (e.g., uncured virgin rubber compositions), curing systems, additional components (e.g., at least one or more additional components), or any combination thereof.

[0136] In some embodiments, micronized cured rubber particle compositions (i.e., recycled rubber compositions) may be mixed with uncured rubber compositions (e.g., uncured virgin rubber compositions), curing systems, additional components, or any Page 25 of 60 12187367v1Attorney Docket No.: 2006702-0042 combination thereof, in a proportion that results in wt% in a range of about 1 wt% to about 50 wt%, of about 1 wt% to about 40 wt%, about 5 wt% to about 35 wt%, or about 10 wt% to about 20 wt% of micronized cured rubber particles in a mixture. For example, in some embodiments, micronized cured rubber particle compositions may be mixed with other components in a proportion that results in a wt% of micronized cured rubber particles of about 10 wt% in a mixture. Without wishing to be bound by any particular theory, wt% of micronized cured rubber particles included in a mixture may be dependent on rubbers utilized in micronized cured rubber particles.

[0137] In some embodiments, uncured rubber compositions (e.g., virgin uncured rubber compositions) are mixed with micronized cured rubber particle compositions (i.e., a recycled component), curing systems, additional components, or any combination thereof, in a proportion that results in a wt% of uncured rubber composition in a mixture of about 1 wt% to about 99 wt%, about 1 wt% to about 50 wt%, about 5 wt% to about 45 wt%, 10 wt% to about 40 wt%, 15 wt% to about 35 wt%, or about 20 wt% to about 30 wt%.

[0138] In some embodiments, uncured rubber compositions (e.g., virgin uncured rubber compositions) are mixed with micronized cured rubber particle compositions (i.e., a recycled component), curing systems, additional components, or any combination thereof, in a proportion that results in a wt% of uncured rubber composition in a mixture of about 50 wt% to about 99 wt%, about 60 wt% to about 99 wt%, about 65 wt% to about 95 wt%, or about 80 wt% to about 90 wt %.

[0139] In some embodiments, curing systems are mixed with micronized cured rubber particle compositions, uncured rubber compositions (e.g., uncured virgin rubber compositions), additional components, or any combination thereof, in a proportion that results in a wt% of curing system in a mixture of about 1 wt% to about 5 wt%.

[0140] In some embodiments, additional components (e.g., fillers, pigments, process oils, curing system, activators, additives, antioxidants, reinforcing agents) are mixed with micronized cured rubber particle compositions, uncured rubber compositions (e.g., uncured virgin rubber compositions), curing systems, or any combination thereof, in a proportion that results in a wt% of the additional components in a mixture of about 1 wt% to about 75 wt%, about 5 wt% to about 70 wt%, 15 wt% to about 65 wt%, or 15 wt% to about 60 wt%. Page 26 of 60 12187367v1Attorney Docket No.: 2006702-0042 3. Shaping

[0141] In some embodiments, preparing recycled rubber materials comprises shaping. In some embodiments, shaping occurs after mixing and before curing a recycled rubber material. A step of shaping can be performed, for example, by extrusion, molding, calendering, etc. Extruders can be used to prepare recycled rubber products from recycled rubber materials in accordance with the present disclosure. They are used in general to produce long continuous products or various profiles that can later be cut to length. Calenders can be used to make wide sheeting. In some embodiments, shaping is performed by calendering a recycled rubber material under conditions that do not cure the material to form a sheet. In transfer and injection molds, a recycled rubber material is forced through channels into a mold chamber of the required shape, where it is cured under pressure. 4. Curing / Vulcanization / Molding

[0142] Typically, curing is carried out under a pressure in a tool, which is heated by steam or thermal oil or electricity to temperatures at which the interlinking reaction takes place. Exemplary tools include, but are not limited to, presses (e.g., rotary curing presses [rotocures], e.g., double belt presses), molds, and / or forced air ovens in-line with extrusion systems. Cure conditions can be several minutes or seconds at an elevated temperature. In some embodiments, an elevated temperature is in a range of about 220 °F to about 380 °F. In some embodiments, an elevated temperature is within a range of about 240 °F to about 320 °F. In some embodiments, an elevated temperature is about 340 °F to about 380 °F. In some embodiments, an elevated temperature is about 340 °F to about 400 °F. In some embodiments, an elevated temperature is about 220 °F, about 230 °F, about 240 °F, about 250 °F, about 260 °F, about 270 °F, about 280 °F, about 290 °F, about 300 °F, about 310 °F, about 320 °F, about 330 °F, about 340 °F, about 350 °F, about 360 °F, about 370 °F, about 380 °F, about 390 °F, about 400 °F, about 500 °F. In some embodiments, an elevated temperature is in a range of about any two values above.

[0143] In general, processes for preparing a recycled rubber product from a recycled rubber material, including mixing and / or curing, are carried out under a pressure greater than 1 atm, or at near atmospheric pressure. Operation pressures can vary at different steps and / or during one step of the processes. In some embodiments, a pressure is within a range of about 40 psi to about 2000 psi. Depending on desired physical properties of the resulting recycled rubber product, different pressures are used. In certain embodiments, a pressure is in a range Page 27 of 60 12187367v1Attorney Docket No.: 2006702-0042 of about 40 psi to about 100 psi. Without wishing to be bound to any particular theory, it is believed that a pressure range of about 40 psi to about 100 psi is suitable for making a sheet. In certain embodiments, a pressure is within a range of about 500 psi to about 2000 psi. 5. Optional Steps

[0144] In some embodiments, methods for preparing recycled rubber materials comprises optionally de-vulcanizing micronized cured rubber particle compositions. Without wishing to be bound by any particular theory, de-vulcanizing micronized cured rubber particle compositions of the present disclosure may be useful for formulating and / or mixing micronized cured rubber particle compositions with uncured virgin rubber compositions.

[0145] In some embodiments, optional de-vulcanizing comprises mixing micronized cured rubber compositions with any of a variety of de-vulcanization chemicals, for example, using a mixer, such as Haake internal mixer. By way of non-limiting example, de- vulcanization chemicals may be or comprise D-LINK-R and / or STRUKTOL WB-21. In some embodiments, de-vulcanization chemicals may be mixed with micronized cured rubber compositions at certain ratios. For example, a ratio of an exemplary micronized cured rubber composition to D-LINK-R may be within a range of about 25:1 to about 5:1, e.g., about 20:1 to about 10:1. In a non-limiting example, an exemplary ratio of micronized cured rubber composition to D-LINK-R is about 17:1. As another example, a ratio of an exemplary micronized cured rubber composition to STRUKTOL WB-21 may be within a range of about 100:1 to about 5:1, e.g., about 75:1 to about 25:1. In a non-limiting example, an exemplary micronized cured rubber composition to D-LINK-R may about 50:1.

[0146] In some embodiments, methods for preparing recycled rubber materials comprises optionally screening the composition of micronized cured rubber particles to produce a composition of micronized cured rubber particles having a particular particle size distribution. Screening may comprise any of a variety of methods or systems which sort micronized cured rubber particles according to size, for example, by sifting / sieving.

[0147] In some embodiments, methods for preparing recycled rubber materials do not comprise screening the composition of micronized cured rubber particles. In certain embodiments, material being screened by, for example, sifting / sieving will agglomerate and ball up, which blocks (i.e., clogs) the screens. An advantage of embodiments of methods and processes described herein is that micronized particles generated using an abrasion wheel do Page 28 of 60 12187367v1Attorney Docket No.: 2006702-0042 not require re-circulation to attain a small size. Re-circulation can result in agglomeration of fine particles and blockage.

[0148] In some embodiments, for example as shown in FIG.2, processes for preparing recycled rubber materials (200) comprise optionally processing finished material into micronized powder (255) for use in methods and compositions described herein. For example, in some embodiments, a roll of rubber (245) can be cut into trims (e.g., using a slitter) (250). Trims may then be micronized into powder for recycling (255). Characteristics of Recycled Rubber Materials

[0149] In many embodiments, recycled rubber materials of the present disclosure can be characterized as having substantially similar physical properties and / or visual properties as a reference rubber material. For example, in some embodiments, reference rubber materials are the same as or similar in composition to cured rubber materials but do not include a recycled rubber component. As another example, in some embodiments, reference rubber materials may be cured virgin rubber materials of the same or similar composition to the recycled rubber material but do not include a recycled rubber component. In some embodiments, reference rubber materials are cured rubber materials of the same or similar composition to the recycled rubber material and comprise micronized cured rubber particles (i.e., a recycled rubber component) that have been de-vulcanized.

[0150] In some embodiments, substantially similar physical properties may be characterized by measuring a difference in physical properties between recycled rubber materials and reference rubber materials using one or more tests. In some embodiments, measured differences in physical properties between recycled rubber materials and reference rubber materials are less than 20%, less than 10%, or less than 5% different.

[0151] In some embodiments, any of a variety of tests may be utilized for measuring differences in physical properties. Exemplary testing methods include: Density (e.g., in accordance with ASTM D-297), Durometer Shore A (e.g., in accordance with ASTM D- 2240), Tensile Strength at Break (e.g., in accordance with ASTM D-412), Elongation (e.g., in accordance with ASTM D-412), Compressive Stress test (e.g., in accordance with ASTM D- 624 and / or ASTM D-395), Tear strength (e.g., in accordance with ASTM D-624), Abrasion NBS (e.g., in accordance with ASTM D-1630), Ozone resistance (e.g., in accordance with Page 29 of 60 12187367v1Attorney Docket No.: 2006702-0042 ASTM D1171), Oil resistance (e.g., in accordance with ASTM D471), Heat Ageing (e.g., in accordance with ASTM D573), and Cold Resistance (e.g., in accordance with ASTM D2137). Exemplary Uses

[0152] In some embodiments, recycled rubber materials of the present disclosure may be utilized as products in any of a variety of uses, forms, and / or structures as conventional rubber materials and products, such as cured rubber materials like cured virgin rubber materials or cured recycled rubber materials prepared by conventional methods and systems. By way of non-limiting example, such products may be tires, flooring, gaskets, belting, industrial rubber doors, hose manufacturing, rubber lining, consumer products, etc. EXEMPLIFICATION Example 1: Generation of Micronized Recycled Rubber Particles and Testing of the Same

[0153] The present Example demonstrates a process of recycling rubber materials by abrading the rubber material into composition comprising micronized cured rubber particles and incorporating the composition into uncured rubber compositions (e.g., virgin uncured rubber compositions). The methods described herein provide a simple, efficient, and less costly means for recycling rubber compositions, where the recycled rubber materials are characterized as having substantially the same properties and performance as non-recycled rubber materials.

[0154] Additionally, the methods described herein demonstrate that a rubber material may be incorporated into a virgin rubber composition to form a partially recycled material without de-vulcanization treatment, and result in a composition that achieves substantially the same visual and physical characteristics as corresponding compositions without a recycled rubber component or with a recycled rubber component that was de-vulcanized. 1. Rubber Compositions

[0155] In this Example, five different types of rubber in the form of rubber trim that was previously discarded from production were used and tested for their ability to be micronized and incorporated into virgin rubber materials. The five different types of rubber tested were as follows: Natural Rubber (NR Formula 1), EPDM (EPDM Formula 1), SBR Page 30 of 60 12187367v1Attorney Docket No.: 2006702-0042 (SBR Formula 1), Chloroprene (CR Formula 1), and Nitrile (NBR Formula 1). The formulation of the five types of rubber used are shown below in Tables 1-5. (i) Table 1: Compound formula: SBR Formula 1 Ingredient PHR Styrene-butadiene rubber 80.0 Chloroprene 5.0 Acrylonitrile butadiene rubber 15.0 Filler 108 Carbon-Black 43 Process oil 46 Cure package and additives 15.0 (ii) Table 2: Compound formula: EPDM Formula 1Ingredient PHR Ethylene propylene diene monomer 100 Carbon-black 198.0 Filler 78 Process oil 115 Cure package and additives 13.3 (iii) Table 3: Compound formula: NR Formula 1 Ingredient PHR Natural rubber 100.0 Filler 30.0 Silica 20.0 Process oil 20.0 Cure package and additives 12.9 (iv) Table 4: Compound formula: CR Formula 1 Ingredient PHR Styrene-butadiene rubber 35.0 Chloroprene 55.0 Acrylonitrile butadiene rubber 10.0 Filler 61.2 Carbon-Black 75.0 Process oil 46.1 Page 31 of 60 12187367v1Attorney Docket No.: 2006702-0042 Cure package and additives 21.5Table 5:Compound formula: NBR Formula 1 Ingredient PHR Styrene-butadiene rubber 25.0 Acrylonitrile butadiene rubber 75.0 Filler 117.0 Sillica 15.0 Process oil 20.0 Cure package and additives 14.1 2. Abrasion Treatment

[0156] The rubber trims were fed into an exemplary unit containing an abrading wheel (see FIG.3). The rubber trim was presented to the abrading wheel at a constant pressure and at a 45° angle and a gap of 0.003 inches between the abrading wheel and trim feed system. The abrading wheel comprises a steel (A36) wheel with diamond electroplating. The rubber trims were abraded to form a granulated powder of micronized rubber particles.

[0157] The resulting micronized rubber particles of each kind of rubber trim are shown in FIG.4 and FIG.5. As shown in FIG.4, the micronized SBR rubber trims achieved a fine powder (Panels A-C) and under a microscope lens, the rubber particles appeared to have an open, porous “popcorn” structure, with a high surface area, and a size of less than 600µm was achieved for all grits (i.e., 100 grit, 40 / 50 grit, and 20 / 30 grit) as shown in FIG.4, Panels A-C . Similar results were achieved for the micronized EPDM rubber trims as shown in FIG.4 (Panels D-F). In contrast, the resulting rubber particles generated from the natural rubber trims appeared to be ribbon-shaped and larger in size (less than 5mm) (Panel G and Panel H) but also appear to be agglomerated.

[0158] Table 6 below shows, the general ease of granulation by reporting the particle size and output yield (%) of particle size, the particle size as measured using a QICPIC® system, the Sauter mean diameter (SMD) as measured with the QICPIC® system, the output rate (ft / min), and corresponding machine parameters (e.g., abrading wheel abrasive grit value, wheel diameter, wheel speed, tangential speed) which generated the micronized rubber particles for each of the noted rubber materials. Page 32 of 60 12187367v1Attorney Docket No.: 2006702-0042 (i) Table 6: Micronized Rubber Particles Particle Size Output Wheel Wheel TangentialDescriptionGritSieving* QICPIC® rate diameter speed speed (Particle Size and Particle Size) (ft / min) (ft / min) ( (in) (rpm) Yield) EXEMPLARY UNIT A 100 98% < 600 µm - 0.15 SBR 40-50 98% < 600 µm - 0.33 20-30 95% < 600 µm - 0.42 100 97% < 600 µm - 0.17 8 800 1675 EPDM 40-50 98% < 600 µm - 0.40 20-30 = * - 0.97NR100 85% < 4750 µm* - 0.40 EXEMPLARY UNIT B 1-2% > 850 µm* D50: 159 µm 10-40% 850-600 1000 - 6675 -SBR100D99: 558 µm 1.0 – 1.5 25.5 µm* 1500 10000 SMD: 132 µm 60-^^^^^^^^^^^P* D50: 300 µmSBR20-30 -D99: 965 µm SMD: 180 µm D50: 300 µmEPDM20-30 - D99: 880 µm 3.0 25.5 1500 10000 SMD: 180 µm D50: 305 µmCR20-30 -D99: 697 µm SMD: 236 µm Page 33 of 60 12187367v1Attorney Docket No.: 2006702-0042 D50: 242 µmNBR20-30 -D99: 743 µm SMD: 165 µm *Agglomeration phenomenon which makes measurements difficult and variable.

[0159] Because the micronized rubber generated from synthetic rubber trims (i.e., SBR and EPDM rubber trims) achieved a small size (no greater than 600µm on average), and an open, porous structure, these materials were deemed more likely to successfully incorporate into virgin rubber materials and be successfully recycled without further chemical processing (e.g., de-vulcanization).

[0160] Without wishing to be bound by any theory, an agglomeration phenomenon makes particle size measurements difficult and variable by sieve analysis. Accordingly, particle size measurements were tested using laser diffraction particle size analysis with dynamic imaging to confirm particle size and distribution. A QICPIC® system from Sympatec was used to measure particle size distribution for micronized rubber processed from Exemplary Unit B. The Sauter mean diameter (SMD) is a representation of the particle size if these particles were a perfect sphere as represented by the surface area as taken using dynamic imaging. D50 and D99 correspond to points on a particle size distribution curve. D50 is representative of the median particle size. At D50, 50% of the particles are smaller than the D50 value. At D99, 99% of the particles are smaller than the D99 value.

[0161] As shown in Table 6, increasing the diameter of an abrasion wheel increases the output rate for a given wheel abrasiveness (grit). Increasing the wheel abrasiveness (grit 100 to grit 20 / 30) increases the output rate. Powder size also increases with higher abrasiveness of a wheel, but remains well within acceptable ranges for recyclability as shown herein.

[0162] Further, exemplary rubber formulations presented in Table 6 could also be tested using gas adsorption surface area analysis (e.g., Brunauer-Emmett-Teller (BET) analysis) to confirm micronized rubber particles have high surface roughness / high surface area. Page 34 of 60 12187367v1Attorney Docket No.: 2006702-0042 3. Rubber Formulations

[0163] Micronized powders described in this example were then incorporated into virgin rubber compositions (non-vulcanized, i.e., uncured) and subsequently cured to generate a new rubber material comprising a recycled rubber component.

[0164] The virgin rubber formulations used were the same as those of the recycled rubber trim shown in Tables 1-5, and the micronized rubber particles from the corresponding formulation were incorporated into the virgin rubber compositions so that about 10% of the final composition was made up of the recycled rubber (micronized rubber particles). Formulations for each composition were tested with the untreated micronized rubber particles. The process (100) of mixing, formulating and curing the rubber compositions is shown in FIG.1, and includes: mixing the virgin rubber materials with the micronized rubber particles or without (control) (110); calendering the rubber formulation into sheets (i.e., “preforms”) (115); heat molding the preforms (i.e., vulcanization and molding) (120). Additional steps for production include sanding and trimming the cured rubber (125), applying a surface coating (a type of surface finishing) (130), and inspecting / packaging the material (135), producing a finished product (140).

[0165] Once the rubber materials were vulcanized and molded, various properties of each rubber were examined. Tables 7-11 below show the various tests that were performed for each composition. For each composition, there was a control sample (without a recycled rubber component), a sample that includes the untreated micronized rubber particles at about 10% (“with Rubber Crumb”). Properties tested for each were performed in accordance with the present disclosure. The target measurements for each test based on the material are also provided. Next, recycled rubber formulations were prepared in accordance with the present disclosure, as presented in Tables 1-5 and compared to virgin rubber formulations. The virgin rubber formulations used were the same as those of the recycled rubber trim shown in Tables 1-5, and the micronized rubber particles from the corresponding formulation were incorporated into the virgin rubber compositions so that about 10% of the final composition was made up of the recycled rubber (micronized rubber particles). In some cases, up to 40% of the final composition was made up of the recycled rubber, for example SBR after being granulated with a 100 grit abrading wheel. Formulations for each composition tested were tested with both the untreated micronized rubber particles. Page 35 of 60 12187367v1Attorney Docket No.: 2006702-0042 (i) Table 7A: SBR Formula 1 Results Laboratory small mixer Laboratory small mixer Exemplary Unit Grit (40-50) recycle powder Grit (20-30) recycle powder A Target Properties Control 10% Control 10% Density (g / cm3) 1.32 1.33 1.35 1.30 1.31 Hardness (shoreA) 60 ± 5 60 59 59 62 Tensile (Psi) 1000 min. 1183 1313 1220 1235 Elongation (%) 300 min. 320 375 324 321 Tear (Psi) - 171 174 158 143 Compression set 22hrs@100°C 80 max. 24 24 26 23 (ii) Table 7B: SBR Formula 1 Results Laboratory small mixer Industrial 11D mixer Exemplary Unit Grit (100) recycle powder Grit (100) recycle powder B Target Properties Control 10% 20% 30% 40% Control 10% Density (g / cm3) 1.32 1.35 1.35 1.34 1.34 1.34 1.34 1.34 Hardness (shoreA) 60 ± 5 61 61 63 64 64 60 62 Tensile (Psi) 1000 min. 1310 1212 1302 1147 1036 1114 1118 Elongation (%) 300 min. 367 358 344 318 276 391 371 Tear (Psi) - 160 153 149 145 137 167 148 Abrasion NBS (%) - 44 43 44 44 45 45 46 Compression set 22hrs@100°C 80 max. 24 27 26 28 28 38 37 (iii) Table 7C: SBR Formula 1 Results Laboratory small mixer Industrial 11D mixer Exemplary Unit Grit (20-30) recycle powder Grit (20-30) recycle powder B Target Properties Control 10% 20% 30% 40% Control 10% Density (g / cm3) 1.32 1.34 1.34 1.34 1.33 1.33 1.34 1.35 Page 36 of 60 12187367v1Attorney Docket No.: 2006702-0042 Hardness (shoreA) 60 ± 5 63 62 60 60 64 58 62 Tensile (Psi) 1000 min. 1110 1105 1075 939 942 1082 1116 Elongation (%) 300 min. 307 333 326 311 273 392 360 Tear (Psi) - 149 141 138 126 127 - 148 Abrasion NBS (%) - 41 44 44 46 45 - 48 Compression set 22hrs@100°C 80 max. 39 40 39 40 45 - 22 (iv) Table 8A: EPDM Formula 1 Results Exemplary Laboratory small mixer Laboratory small mixer Unit A Grit (40-50) recycle powder Grit (20-30) recycle powder Target Properties Control 10% Control 10% Density (g / cm3) 1.20 1.22 1.22 1.22 1.22 Hardness (shoreA) 60 ± 5 60 60 63 63 Tensile (Psi) 800 min. 1035 894 970 925 Elongation 250% (%) min. 533 464 498 504 Tear (Psi) - 144 124 148 136 Compression set 50% 16 17 19 2hrs@70°C m 18 2 ax. (v) Table 8B: EPDM Formula 1 Results Laboratory small mixer Industrial 11D mixer Properties Target Grit (20-30) Grit (20-30) recycle powder recycle powder Control 10% Control 10% Density (g / cm3) 1.20 1.22 1.22 1.26 1.21 Hardness (shoreA) 60 ± 5 65 65 60 63 Tensile (Psi) 800 min. 881 824 883 847 Elongation (%) 250% min. 478 491 480 564 Tear (Psi) - 123 117 - 130 Page 37 of 60 12187367v1Attorney Docket No.: 2006702-0042 Compression set 22hrs@70°C 50% max. 19 21 - 17 Hardness ± 10 max. 7 5 - 3 Heat Aging 70hrs@100°C Tension -25 max. 5 4 - 2 Elongation -25 max. -19 -21 - -24 Cold resistance -40 °C -46 -46 - -40 Abrasion NBS (%) - 25 25 - 27 (vi) Table 9A: NR Formula 1 Results Exemplary Unit B Laboratory small mixer Target Grit (100) recycle powder Properties Control 10% Density (g / cm3) 1.14 1.14 1.14 Hardness (shoreA) 40 ± 5 40 39 Tensile (Psi) 2000 Min. 2900 2861 Elongation (%) 400% Min. 642 666 Tear (Psi) - 166 170 Abrasion NBS (%) - 74 69 Compression set 22hrs@70°C 50% max. 18 20 (vii) Table 9B: NR Formula 1 Results Exemplary Unit B Laboratory small mixer Target Grit (20-30) recycle powder Properties Control 10% Density (g / cm3) 1.14 1.14 1.14 Hardness (shoreA) 40 ± 5 43 40 Tensile (Psi) 2000 Min. 2827 2697 Elongation (%) 400% Min. 538 767 Tear (Psi) - 202 225 Abrasion NBS (%) - 98 84 Compression set 22hrs@70°C 50% max. 18 21 Page 38 of 60 12187367v1Attorney Docket No.: 2006702-0042 (iix) Table 10: CR Formula 1 Results Laboratory small mixer Industrial 11D mixerGrit (20-30) recycle Grit (20-30) recycle po erties Target pow wder Prop der Control 10% Control 10% Density (g / cm3) 1.32 1.32 1.31 1.32 1.32 Hardness (shoreA) 60 ± 5 63 63 56 60 Tensile (Psi) 900 min. 1188 1120 1398 1406 Elongation (%) 300 min. 304 306 401 422 Tear (Psi) - 166 146 - 152 Abrasion NBS (%) - 42 40 - 35 Compression set (%) 22hrs@100°C 80 max. 37 35 - 37 Hardness + 15 (Shore A) max. 6 8 - 10 Heat Aging Tension 70hrs@100°C (%) -15 max. -10 -10 - 1 Elongation (%) -40 max. -36 -32 - -19 Oil #3 resistance Volume (%) 100 max. 64 62 - 63 70hrs@100°C Ozone resistance 70hrs@40°C Triangle No cracks Pass Pass - Pass (50 PPHM) (ix) Table 11: NBR Formula 1 Results Laboratory small mixer Grit (20-30) recycle Exemplary Unit B powder Target Properties Control 10% Density (g / cm3) 1.46 1.46 1.46 Hardness (shoreA) 60 ± 5 62 62 Tensile (Psi) 1000 min. 1360 1402 Elongation (%) 300 min. 460 480 Tear (Psi) - 144 135 Abrasion NBS (%) 47 47 Page 39 of 60 12187367v1Attorney Docket No.: 2006702-0042 Compression set (%) 22hrs@100°C 50 max. 35 36 Hardness ing ( ±15 max. 2 3 Heat Ag Shore A) 70hrs@100°C Tension (%) ±30 max. 4 -2 Elongation (%) -50 max. -25 -25 Oil #3 resistance 70hrs@100°C Volume (%) 60 max. 31 32

[0166] As summarized in Tables 7 - 11, it was found that, by using processes and methods of the present example, all target properties for the various synthetic and natural rubber compositions are maintained when 10% of the formulation is replaced by the recycled micronized rubber particles. In the case of the SBR composition, it was demonstrated that the target properties are essentially maintained when 40% of the formulation is replaced by the recycled micronized rubber particles. Target properties were met for all tested synthetic and natural rubbers for each of the different abrasion wheel grits tested. Example 2: Testing Effect of De-Vulcanization on Micronized Rubber Particles 1. De-vulcanization

[0167] The present example demonstrates whether further chemical processing of the granulated rubber was necessary for incorporating back into a virgin rubber compositions. A portion of exemplary granulated rubber formulations described herein (e.g., SBR, EPDM, and NR) were subjected to a de-vulcanization step.

[0168] The rubber crumb compositions were de-vulcanized. De-vulcanization formulations are shown in Tables 12-14 below, and include D-LINK-R-NR and STRUKTOL WB-21, in addition to varying amounts of the original rubber composition (EPDM, SBR, or NR).

[0169] Such a process is used on cured rubber products and to convert them back to pliable and re-mouldable compositions. D-LINK-R-NR was added using a high shear rate using a Haake internal mixer. The mixture was mixed until able to form a continuous sheet and holds itself up on the mill bowl, as a sign that the cross-links have been broken. Page 40 of 60 12187367v1Attorney Docket No.: 2006702-0042 2. Rubber Formulations

[0170] The de-vulcanized (i.e., treated) and untreated particles were then incorporated into virgin rubber compositions (non-vulcanized, i.e., uncured) and subsequently cured to generate a new rubber material comprising a recycled rubber component.

[0171] The virgin rubber formulations used were the same as those of the recycled rubber trim shown in Tables 1-3, and the micronized rubber particles from the corresponding formulation were incorporated into the virgin rubber compositions so that about 10% of the final composition was made up of the recycled rubber (micronized rubber particles). Formulations for each composition tested were tested with both the untreated micronized rubber particles and the de-vulcanized (treated) micronized rubber particles. The process of mixing, formulating and curing the rubber compositions is shown in FIG.1, and includes: mixing the virgin rubber materials with the micronized rubber particles or without (control); calendering the rubber formulation into sheets (i.e., “preforms”); heat molding the preforms (i.e., vulcanization and molding). Additional steps for production include sanding and trimming the cured rubber, applying a surface coating, and inspecting / packaging the material.

[0172] Once the rubber materials were vulcanized and molded, various properties of each rubber were examined. Tables 12-14- below show the various tests that were performed for each composition. For each composition, there was a control sample (without a recycled rubber component), a sample that includes the untreated micronized rubber particles at about 10% (“with Rubber Crumb”), and a sample that includes treated, i.e., de-vulcanized rubber particles (“DVLC”). The rows of “added ingredient” include additives used for the de- vulcanization. For each test, the ASTM test protocol is provided. The typical measurements for each test based on the material are also provided. Page 41 of 60 12187367v1Attorney Docket No.: 2006702-0042 Results (i) Table 12: SBR Compositions SBR With SBRRubber With Crumb DVLC RUB. CRUMB 0 35 35 0.32 Styrene- butadiene 0 0 2.1 ADDED INGREDIENT rubber D-LINK-R- NR 0 0 2.1 STRUKTOL WB-21 0 0 0.7 TEST ASTM Typical METHOD Properties Density (g / cc) D-297 1.32 1.33 1.33 1.33 Durometer Shore A D-2240 60 63 63 66 Tension (PSI) D-412 1000 1008 992 926 Elongation BASIC (%) D-412 300 389 394 335 PROPERTIES COMP. SET- A, 22H 70°C, D-395 22 20 17 25% COMP. SET- B, 22H 100°C, D-395 80 max. 33 30 29 25% Cold Flexibility D2137 / -32 -32 -32 (°C) D746B OTHERS Tear (LB / PO) D-624 207 175 180 Abrasion NBS (%) D-1630 44 41 41 Page 42 of 60 12187367v1Attorney Docket No.: 2006702-0042 (ii) Table 13: EPDM Compositions With With EPDMRubber DVLC Crumb (10%) RUB. CRUMB 0 55 55 0.32 EPDM 0 0 6.88 RECIPE EPDM 0 0 6.88 D-LINK- R-NR 0 0 3.3 STRUKTO L WB-21 0 0 1.1 ASTM TEST METHO Typical D Properties Density (g / cc) D-297 1.2 1.24 1.24 1.23 Durometer Shore A D-2240 60 60 61 59 Tension (PSI) D-412 800 879 942 913 BASIC Elongation (%) D-412 300 559 536 502 PROPERTI COMP. SET- ES A, 22H 70°C, D-395 50 max. 14 13 8 25% COMP. SET- B, 22H 100°C, D-395 33 36 24 25% Cold D2137 / Flexibility(°C) D746B -40 -38 -38 -40 OTHERS Tear(LB / PO) D-624 142 140 149 Abrasion NBS (%) D-1630 21 23 22 Page 43 of 60 12187367v1Attorney Docket No.: 2006702-0042 (iii) Table 14: Natural Rubber Compositions NR With With Formul Rubber DVL ation crumb C (10%) RUB. CRUMB 0 20 20 0.32 Natural E R 0 0 2.4 RECIP ubber D-LINK-R- NR 0 0 1.2 STRUKTOL WB-21 0 0 0.4 TEST ASTM Typical METHOD Properties Density (g / cc) D-297 1.14 1.14 1.14 1.14 Durometer Shore A D-2240 40 37 34 39 BASIC Tension (PSI) D-412 2500 3204 2594 2510 PROPER Elongation (%) D-412 700 707 699 652 TIES Tear(Psi) D-624 186 158 174 COMP. SET- A, 22H 70°C, D-395 50 max. 27 32 16 25% Cold D2137 / Flexibility (°C) D746B -40 -48 -48 -48 OTHERS Abrasion NBS (%) D-1630 68 68 60 Visual aspect n / a OK OK OK

[0173] Results in Table 12 and 13 indicate that for the recycled SBR and EPDM rubber materials, micronized rubber particles of the desired structure and of size that is below 600 microns were recovered from the granulating unit. Table 12 and Table 13 show that all physical properties that were tested were maintained when 10% of the formulation is replaced by the recycled micronized rubber particles. Surprisingly, the de-vulcanization of the recycled rubber does not appear to enhance or deteriorate the physical properties.

[0174] For the natural rubber (NR) materials tested in the present example, an open and porous “popcorn structure” was achieved, but the desired size reduction was not. The size of the rubber particles obtained from the natural rubber trims were significantly larger. Page 44 of 60 12187367v1Attorney Docket No.: 2006702-0042 Without wishing to be bound by any theory, the larger particle size produced may be due to rubber material aggregation upon granulation. In the present example, no sieving was used.

[0175] As shown in Table 14, compositions using NR showed no change or minimal change in physical properties. Since size may be an important feature in whether the final recycled rubber maintains its physical properties, further studies will be performed using a granulating unit that can achieve a higher speed and power. Surprisingly, however, as with the EPDM and SBR rubber materials, there was no advantage shown to applying the de- vulcanization procedure to the rubber particles, as evidenced by the similar physical properties between the two test groups.

[0176] Overall, granulation into micronized rubber particles through a tearing mechanism making use of an abrasive wheel generates an open powder structure of small size. If the particle size is sufficiently small, re-incorporation of the powder is achieved without loss in physical properties. Here the recycled rubber material was re-incorporated so that it made up about 10% of the final rubber material. Example 3: Morphology and Particle Size Distribution

[0177] The present example presents a comparison between the morphology of styrene-butadiene rubber (SBR) and Natural Rubber (NR) powders generated using an exemplary unit employing an abrading wheel according to technologies described herein. Formulas for SBR and NR powders of this example are described in Example 1, Tables 1 and 3, respectively. 1. Morphology Comparison of SBR

[0178] FIG.6 shows scanning electron microscope (SEM) images of SBR powders generated using a Condux® unit (FIG.6, Panels A-C), an exemplary unit using a 100 grit abrading wheel (FIG.6, Panels D-F), and an exemplary unit using a 20 / 30 grit abrading wheel (i.e., an abrading wheel with both 20 and 30 grit powders) (FIG.6, Panels G-I). The Condux® unit is representative of powders created using a traditional granulation process performed through a shearing / grinding mechanism.

[0179] The Condux® unit results in production larger, unitary particles as can be seen in the 200X images. With the exemplary units employing either of the two different abrading wheels, the powder is much finer and more interconnected. The 1000X and 5000X images Page 45 of 60 12187367v1Attorney Docket No.: 2006702-0042 show the finer structure and surface asperities (i.e., holes) compared to a more closed structure as produced using the Condux® unit. Little difference in morphology is observed between SBR powder generated by with 100 grit versus 20-30 grit abrading wheels. 2. Particle Size Distribution of SBR

[0180] FIG.7 and Table 15 (presented below) show the particle size distribution of SBR powders as measured through laser diffraction with dynamic imaging. (i) Table 15: Styrene-Butadiene Rubber Particle Distribution Condux® Exemplary Exemplary Process Unit B Unit B (microns) Abrasive Abrasive Process - Process – Grit 100 Grit 20-30 (microns) (microns) D10 1089 75 89 D25 1456 107 142 D50 1609 159 300 D80 1796 284 789 D90 1858 364 880 D99 1914 558 965 Sauter mean 1404 132 180 diameter (SMD)

[0181] A QICPIC® system from Sympatec was used to measure particle size distribution. Each panel of FIG.7 shows the distribution density and cumulative distribution (%) plotted on a logarithmic graph of particle size.

[0182] The shearing / grinding powdering process performed using a Condux® system yields particle sizes in the range of 1000 to 2000 microns. On Exemplary Unit B with a 100 grit abrasive wheel, particle size is generally below 500 microns. With an abrasive wheel with 20-30 grit (i.e., a higher abrasiveness), the particle size distribution is bi-modal as shown in, for example, FIG.7. Even though the particle size distribution is bimodal, the D50 remains at 300 microns. Page 46 of 60 12187367v1Attorney Docket No.: 2006702-0042

[0183] The Sauter mean diameter (SMD) is a representation of the particle size if these particles were a perfect sphere as represented by the surface area as taken using dynamic imaging. The SMD shows that the particle size of the powder is significantly smaller than what is obtained with the Condux® powdering-based technology. 3. Morphology and Particle Size Distribution of NR

[0184] FIG.8 shows scanning electron microscope (SEM) images of natural rubber (NR) powders generated using an exemplary unit using a 20 / 30 grit abrading wheel and particle size distribution of NR powders as measured through laser diffraction with dynamic imaging. NR powders were generated using the formula found in Table 3.

[0185] The morphology of the NR powder is similar to the morphology of as seen with SBR powders (e.g., as shown in FIG.6).

[0186] Table 16 (presented below) shows the particle size distribution of NR powders (i.e., as shown in FIG.8) as measured using laser diffraction with dynamic imaging technology. (ii) Table 16: Natural Rubber Powder Particle Distribution Grit 20-30 (microns) D10 279 D25 361 D50 616 D80 1054 D90 1130 D99 1198 Sauter mean 472 diameter (SMD)

[0187] A QICPIC® system from Sympatec was used to measure particle size distribution in FIG.8 and Table 14. FIG.8 shows the distribution density and cumulative distribution (%) plotted on a logarithmic graph of particle size. As shown in FIG.8, the Page 47 of 60 12187367v1Attorney Docket No.: 2006702-0042 distribution of the NR particles is a bimodal distribution and is of a higher dimension as compared to synthetics (e.g., SBR).

[0188] The Sauter mean diameter (SMD) is a representation of the particle size if these particles were a perfect sphere as represented by the surface area as taken using dynamic imaging. The SMD shows that the particle size of the NR powder is about 472 microns. Example 4: Comparing Micronization Processes

[0189] In this Example, different processes for micronization were compared. A powdering process conducted using a Condux® powdering-based technology and technologies discussed herein which employ abrading wheels to micronize rubbers with formulations in accordance with formulations as provided in Example 1, Tables 1-5. The Condux® powdering-based technology is a technique that has been used in the field to granulate.

[0190] Micronized powders described in this example were then incorporated into virgin rubber compositions (non-vulcanized, i.e., uncured) and subsequently cured to generate a new rubber material comprising a recycled rubber component.

[0191] The virgin rubber formulations used were the same as those of the recycled rubber trim shown in Tables 1-5, and the micronized rubber particles from the corresponding formulation were incorporated into the virgin rubber compositions so that about 10% of the final composition was made up of the recycled rubber (micronized rubber particles). Formulations for each composition were tested with the untreated micronized rubber particles.

[0192] Table 17 shows various test results on SBR composition prepared with recycle content using various grit sizes comparing to the Condux process. Properties tested for each were performed in accordance with the present disclosure. The control values for each test based on the material are also provided. Recycled rubber formulations were prepared in accordance with the present disclosure, as presented in, for example, Table 1. Micronized rubber particles from the corresponding SBR 1 formulation were incorporated into the virgin rubber compositions so that either about 10% or 20% of the final composition was made up of the recycled rubber (micronized rubber particles). Page 48 of 60 12187367v1Attorney Docket No.: 2006702-0042 (i) Table 17: SBR Formula 1 Results ǻ versus control ǻ versus control 10% of recycled powder 20% of recycled powder Control Properties Exemplary Values Exemplary Exemplary Exemplary Condux® Unit B Unit B Condux® Unit B Unit B G100 G20 / 30 G100 G20 / 30 Hardness 60 + 2% 0% -2% +2% +3%-5%(shore A)Tensile (Psi)1200 -15% -7% 0% -30% -7%-3%Elongation (%)300 -8% -2% 8% -24% -2%6%Tear (Psi)155 + 3% -4% -6% -4% -4%-8% Compression set 30 +17% +13% +3% +17% 13%0%22hrs@100°C

[0193] The results in Table 17 show that materials prepared using micronized particles from a Condux® powdering unit, generally, had values that varied much greater from control values than those materials using micronized rubber powders prepared using abrading-wheel based processes described herein using either 100 grit (G100) or 20-30 grit (G20 / 30) abrading wheels. Accordingly, these results demonstrate improved properties when using micronized rubber powders prepared using processes as provided herein. EQUIVALENTS

[0194] Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. The scope of the present invention is not intended to be limited to the above Description, but rather is as set forth in the following claims: Page 49 of 60 12187367v1

Claims

Attorney Docket No.: 2006702-0042 CLAIMS We claim:

1. A method for producing a recycled rubber material, the method comprising: (i) obtaining a previously cured rubber material; (ii) granulating the previously cured rubber material in order to generate a composition of micronized cured rubber particles; and (iii) mixing the composition of micronized cured rubber particles with an uncured rubber composition.

2. The method of claim 1, wherein the method does not comprise screening the composition of micronized cured rubber particles.

3. The method of claim 1 or 2, wherein the method further comprises performing a partial or complete de-vulcanization of the composition of micronized cured rubber particles.

4. The method of claim 1 or 2, wherein the method does not comprise performing a partial or complete de-vulcanization of the composition of micronized cured rubber particles.

5. The method of any one of claims 1-4, wherein the method further comprises curing the mixture of micronized cured rubber particles and uncured rubber material.

6. The method of any one of claims 1-5, wherein the mixture comprises at least about 5 wt%, at least about 10 wt%, at least about 15 wt%, at least about 20 wt%, at least about 25 wt%, at least about 30 wt%, at least about 40 wt%, or at least about 50 wt% of the composition of micronized cured rubber particles.

7. The method of any one of claims 1-6, wherein at least 90% of the micronized cured rubber particles have a particle size less than about 5600 µm, less than about 4750 µm, less than about 4000 µm, less than about 3350 µm, less than about 3170 µm, less than about 2800 µm, less than about 2360 µm, less than about 2000 µm, less than about 1700 µm, less than about 1400 µm, less than about 1180 µm, less than about 1000 µm, less than about 850 Page 50 of 60 12187367v1Attorney Docket No.: 2006702-0042 µm, less than about 710 µm, less than about 600 µm, less than about 500 µm, less than about 425 µm, less than about 355 µm, less than about 300 µm, or less than about 250 µm.

8. The method of any one of claims 1-7, wherein at least 99% of micronized cured rubber particles have a particle size of about 1000 µm or less, about 965 µm or less, about 950 µm or less, about 880 µm or less, about 800 µm or less, about 743 µm or less, about 697 µm or less, about 558 µm or less.

9. The method of any one of claims 1-8, wherein at least 50% of micronized cured rubber particles have a particle size of about 350 µm or less, about 325 µm or less, about 305 µm or less, about 300 µm or less, about 242 µm or less, about 159 µm or less.

10. The method of any one of claims 1-9, the Sauter mean diameter (SMD) of micronized cured rubber particles is about 500 µm or less, about 400 µm or less, about 300 µm or less, about 250 µm or less, about 236 µm or less, about 180 µm or less, about 165 µm, about 132 µm or less.

11. The method of claims 7-10, wherein the particle size and / or a particle size distribution is characterized by sieve analysis and / or laser diffraction particle size analysis.

12. The method of claim 4, wherein the mixture comprising the composition of micronized cured rubber particles and uncured rubber material is substantially free of de- linking accelerators.

13. The method of any one of claims 1-12, wherein the previously cured rubber material comprises natural rubber and / or at least one synthetic rubber.

14. The method of claim 13, wherein the at least one synthetic rubber comprises one or more members selected from the group consisting of: styrene-butadiene rubber (SBR), nitrile rubber, ethylene propylene diene monomer rubber (EPDM), synthetic polyisoprene, chloroprene rubber, butyl rubber, butadiene rubber, ethylene propylene rubber, fluoro- rubber, silicone rubber, and thermoplastic elastomer. Page 51 of 60 12187367v1Attorney Docket No.: 2006702-0042 15. The method of any one of claims 1-14, wherein the uncured rubber composition comprises natural rubber and / or at least one synthetic rubber.

16. The method of claim 15, wherein the at least one synthetic rubber comprises one or more members selected from the group consisting of: styrene-butadiene rubber (SBR), nitrile rubber, ethylene propylene diene monomer rubber (EPDM), synthetic polyisoprene, chloroprene rubber, butyl rubber, butadiene rubber, ethylene propylene rubber, fluoro- rubber, silicone rubber, and thermoplastic elastomer.

17. The method of any one of claims 1-16, wherein the uncured rubber composition further comprises one or more additional components selected from the group consisting of: clay, carbon-black, aromatic process oil, zinc oxide, antioxidant, additives, sulfur, accelerators, calcium carbonate, naphthenic process oil, and silica.

18. The method of any one of claims 1-17, wherein granulating occurs at a rate within a range of about 0.5 ft / min to about 20 ft / min, about 1 ft / min to about 15 ft / min, about 3 ft / min to about 10 ft / min, or about 6 ft / min to about 7 ft / min.

19. The method of any one of claims 1-18, wherein granulating comprises abrading the previously cured rubber material with an abrading wheel, the abrading wheel comprising an abrasive having a grit of at most about 200, at most about 100, at most about 80, at most about 60, at most about 50, at most about 40, or at most about 20.

20. The method of claim 19, wherein the abrasive comprises one or more members selected from the group consisting of diamond, aluminum oxide, corundum, zirconium, ceramics, silicon carbide, and any combination thereof.

21. The method of claim 19 or 20, wherein the abrading wheel operates at a speed of at least about 500 rpm, at least about 1000 rpm, at least about 1500 rpm, at least about 2000 rpm, at least about 2500 rpm, at least about 3000 rpm, at least about 3500 rpm, at least about 4000 rpm, at least about 4500 rpm, or at least about 5000 rpm. Page 52 of 60 12187367v1Attorney Docket No.: 2006702-0042 22. The method of any one of claims 19-21, wherein abrading comprises presenting the previously cured rubber material to the abrading wheel at an angle within a range of about 15°-75°, within a range of about 20°-70°, within a range of about 25°-65°, within a range of about 30°-60° within a range of about 35°-55°, or within a range of about 40°-50°.

23. The method of any one of claims 19-22, wherein abrading comprises presenting the previously cured rubber material to the abrading wheel at an angle of about 30° to about 45°.

24. The method of any one of claims 19-23, wherein abrading comprises presenting the previously cured rubber material to the abrading wheel via a rubber trim feed system.

25. The method of claim 24, wherein there is a gap between the abrading wheel and the rubber trim feed system, the gap being within a range of about 0.001 inches and about 0.01 inches, or about 0.003 inches and about 0.008 inches.

26. The method of any one of claims 19-25, wherein method comprises cooling and / or heating a surface of the abrading wheel during abrading to maintain a temperature within 20°C, within 10°C, within 5°C, within 4°C, within 2°C or less of an initial temperature.

27. A recycled rubber material produced by the method of any one of the preceding claims.

28. The recycled rubber material of claim 27, wherein the recycled rubber material is characterized as having substantially similar physical properties as a reference cured rubber material.

29. The recycled rubber material of claim 28, wherein the difference in physical properties between the recycled rubber material and the reference cured rubber material measured by one or more tests is less than 30%, less than 20%, less than 10%, or less than 5% different.

30. The method of claim 29, wherein the one or more tests comprises one or more members selected from the group consisting of: Density (ASTM D-297), Durometer Shore A Page 53 of 60 12187367v1Attorney Docket No.: 2006702-0042 (ASTM D-2240), Tensile Strength at Break (ASTM D-412), Elongation (ASTM D-412), Compressive Stress Test (ASTM D-624 or ASTM D-395), Tear strength (ASTM D-624), Cold Flexibility (ASTM D-2137 or ASTM D-746B), Abrasion NBS (ASTM D-1630), Oil resistance (ASTM D471), Heat Ageing (ASTM D573), and Cold Resistance (ASTM D2137).

31. The method of any one of claims 28-30, wherein the recycled rubber material is characterized as having substantially similar ozone resistance properties as a reference cured rubber material.

32. The method of claim 31, wherein the ozone resistance properties are measured by an ozone resistance test (ASTM D1171).

33. The recycled rubber material of any one of claims 18-32, wherein the recycled rubber material is characterized as having substantially similar visual properties as a reference cured rubber material.

34. A machine comprising an abrading wheel, wherein the abrading wheel comprises steel and an abrasive having a grit of at most about 200, at most about 100, at most about 80, at most about 60, at most about 50, at most about 40, or at most about 20.

35. The machine of claim 34, wherein the abrasive comprises one or more members selected from the group consisting of diamond, aluminum oxide, corundum, zirconium, ceramics, silicon carbide, and any combination thereof.

36. The machine of claim 34 or 35, wherein the machine further comprises a rubber trim feed system for feeding rubber trim to the abrading wheel.

37. The machine of claim 36, wherein the rubber trim feed system feeds the rubber trim to the abrading wheel at an angle within a range of about 15°-75°, within a range of about 20°-70°, within a range of about 25°-65°, within a range of about 30°-60° within a range of about 35°-55°, or within a range of about 40°-50°. Page 54 of 60 12187367v1Attorney Docket No.: 2006702-0042 38. The machine of claim 36 or 37, wherein the rubber trim feed system feeds the rubber trim to the abrading wheel at an angle within a range of about 30° to about 45°.

39. The machine of any one of claims 34-38, comprising a gap between the abrading wheel and the rubber trim feed system, the gap being within a range of about 0.001 inches and about 0.01 inches, or about 0.003 inches and about 0.008 inches.

40. The machine of claim 39, wherein the machine comprises a system for maintaining the gap between the abrading wheel and the rubber trim feed system.

41. The machine of any one of claims 34-40, wherein the machine comprises a system configured to cool and / or heat the abrading wheel.

42. The machine of any one of claims 34-41, wherein the abrading wheel comprises a water jacketing system.

43. The machine of claim 42, wherein the water jacketing system is configured to limit (or prevent) thermal expansion and / or contraction of the abrading wheel.

44. The machine of claim 42 or 43, wherein the water jacketing system is configured to circulate a fluid through the abrading wheel.

45. The machine of claims 41-44, wherein the system configured to cool / and or heat the abrading wheel is configured to cool an abrading surface of the abrading wheel.

46. The machine of any one of claims 34-45, wherein the rubber trim comprises natural rubber and / or at least one synthetic rubber.

47. The machine of claim 46, wherein the at least one synthetic rubber comprises one or more members selected from the group consisting of styrene-butadiene rubber (SBR), nitrile rubber, ethylene propylene diene monomer rubber (EPDM), synthetic polyisoprene, Page 55 of 60 12187367v1Attorney Docket No.: 2006702-0042 chloroprene rubber, butyl rubber, butadiene rubber, ethylene propylene rubber, fluoro- rubber, silicone rubber, thermoplastic elastomer.

48. The machine of any one of claims 34-47, wherein the abrading wheel is configured to rotate at a speed of at least about 500 rpm, at least about 1000 rpm, at least about 1500 rpm, at least about 2000 rpm, at least about 2500 rpm, at least about 3000 rpm, at least about 3500 rpm, at least about 4000 rpm, at least about 4500 rpm, or at least about 5000 rpm.

49. The machine of any one of claims 34-47, wherein the abrading wheel comprises a diameter of between about 5 inches and about 35 inches and / or a width of between about 1 inch and about 6 inches.

50. The machine of any one of claims 34-49, wherein the machine further comprises a drive belt for driving the abrading wheel.

51. The machine of any one of claims 34-50, wherein after the rubber trim is fed through the machine, the rubber trim is converted into a composition of micronized cured rubber particles.

52. The machine of claim 51, wherein at least 90% of the micronized cured rubber particles have a particle size less than about 5600 µm, less than about 4750 µm, less than about 4000 µm, less than about 3350 µm, less than about 3170 µm, less than about 2800 µm, less than about 2360 µm, less than about 2000 µm, less than about 1700 µm, less than about 1400 µm, less than about 1180 µm, less than about 1000 µm, less than about 850 µm, less than about 710 µm, less than about 600 µm, less than about 500 µm, less than about 425 µm, less than about 355 µm, less than about 300 µm, or less than about 250 µm.

53. The method of either claims 51 or 52, wherein at least 99% of micronized cured rubber particles have a particle size of about 1000 µm or less, about 965 µm or less, about 950 µm or less, about 880 µm or less, about 800 µm or less, about 743 µm or less, about 697 µm or less, about 558 µm or less. Page 56 of 60 12187367v1Attorney Docket No.: 2006702-0042 54. The method of any one of claims 51-53, wherein at least 50% of micronized cured rubber particles have a particle size of about 350 µm or less, about 325 µm or less, about 305 µm or less, about 300 µm or less, about 242 µm or less, about 159 µm or less.

55. The method of any one of claims 51-54, wherein the Sauter mean diameter (SMD) of micronized cured rubber particles is about 500 µm or less, about 400 µm or less, about 300 µm or less, about 250 µm or less, about 236 µm or less, about 180 µm or less, about 165 µm, about 132 µm or less.

56. The machine of any one of claims 35-55, wherein the abrading wheel, when fed rubber trim, granulates the previously cured rubber material at a rate within a range of about 0.5 ft / min to about 20 ft / min, about 1 ft / min to about 15 ft / min, about 3 ft / min to about 10 ft / min, or about 6 ft / min to about 7 ft / min.

57. A recycled rubber composition comprising an uncured rubber component and a previously cured rubber component, wherein the previously cured rubber component comprises micronized cured rubber particles derived from a previously cured rubber material, and the previously cured rubber component is at least about 1 wt%, at least about 5 wt%, at least about 10 wt%, at least about 15 wt%, at least about 20 wt%, at least about 25 wt%, at least about 30 wt%, at least about 35 wt%, at least about 40 wt%, at least about 45 wt%, or at least about 50 wt% of the rubber composition.

58. The rubber composition of claim 57, wherein at least 90% of the micronized cured rubber particles of the previously cured rubber component have a particle size less than about 5600 µm, less than about 4750 µm, less than about 4000 µm, less than about 3350 µm, less than about 3170 µm, less than about 2800 µm, less than about 2360 µm, less than about 2000 µm, less than about 1700 µm, less than about 1400 µm, less than about 1180 µm, less than about 1000 µm, less than about 850 µm, less than about 710 µm, less than about 600 µm, less than about 500 µm, less than about 425 µm, less than about 355 µm, less than about 300 µm, or less than about 250 µm. Page 57 of 60 12187367v1Attorney Docket No.: 2006702-0042 59. The method of claim 57 or 58, wherein at least 99% of micronized cured rubber particles have a particle size of about 1000 µm or less, about 965 µm or less, about 950 µm or less, about 880 µm or less, about 800 µm or less, about 743 µm or less, about 697 µm or less, about 558 µm or less.

60. The method of any one of claims 57-59, wherein at least 50% of micronized cured rubber particles have a particle size of about 350 µm or less, about 325 µm or less, about 305 µm or less, about 300 µm or less, about 242 µm or less, about 159 µm or less.

61. The method of any one of claims 57-60, wherein the Sauter mean diameter (SMD) of micronized cured rubber particles is about 500 µm or less, about 400 µm or less, about 300 µm or less, about 250 µm or less, about 236 µm or less, about 180 µm or less, about 165 µm, about 132 µm or less.

62. The recycled rubber composition of any one of claims 57-61, wherein the uncured rubber component comprises natural rubber and / or at least one synthetic rubber.

63. The recycled rubber composition of claim 62, wherein the at least one synthetic rubber comprises one or more members selected from the group consisting of: styrene- butadiene rubber (SBR), nitrile rubber, ethylene propylene diene monomer rubber (EPDM), synthetic polyisoprene, chloroprene rubber, butyl rubber, butadiene rubber, ethylene propylene rubber, fluoro-rubber, silicone rubber, and thermoplastic elastomer.

64. The recycled rubber composition of any one of claims 57-61, wherein the previously cured rubber component comprises natural rubber and / or at least one synthetic rubber.

65. The recycled rubber composition of claim 64, wherein the at least one synthetic rubber comprises one or more members selected from the group consisting of: styrene- butadiene rubber (SBR), nitrile rubber, ethylene propylene diene monomer rubber (EPDM), synthetic polyisoprene, chloroprene rubber, butyl rubber, butadiene rubber, ethylene propylene rubber, fluoro-rubber, silicone rubber, and thermoplastic elastomer. Page 58 of 60 12187367v1Attorney Docket No.: 2006702-0042 66. The recycled rubber composition of any one of claims 57-65 further comprising one or more additional components selected from the group consisting of: clay, silica, carbon- black, aromatic process oil, zinc oxide, antioxidant, additives, sulfur, accelerators, calcium carbonate, and naphthenic process oil.

67. The recycled rubber composition of any one of claims 57-66, wherein the micronized cured rubber particles have a surface comprising asperities.

68. The recycled rubber composition of claim 67, wherein the surface comprising asperities is characterized by determining a surface area using a gas adsorption analysis.

69. The rubber composition of any one of claims 57-68, wherein the composition is substantially free of rubber de-linking accelerators.

70. In a method of manufacturing an end product from a rubber material, the improvement that comprises using a recycled rubber composition of claim 57 as the rubber material.

71. In a recycled rubber composition, the improvement that comprises incorporating micronized cured rubber particles into the composition.

72. The improvement of claim 71, wherein the incorporating is by a process of any one of claims 1-26. Page 59 of 60 12187367v1

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