Functionalized Reclaimed Elastomer Shear Devulcanization
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Solution Overview
Problem
Reclaimed elastomer materials, such as micronized rubber powder, when functionalized, are limited in their mechanical properties when used in elastomer compositions due to their inert nature, leading to diminished performance characteristics, especially when compared to compositions containing no reclaimed material.
Innovation Solution
The method involves subjecting reclaimed elastomer materials to shear at temperatures less than 100 °C, specifically targeting inter-chain bonds in particles of 0.422mm (40 mesh) or smaller, using a two-roll mill process with a modifier like urea or urea derivatives to break cross-links, resulting in functionalized particles that can enhance mechanical properties when used in elastomer compositions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If reclaimed elastomer materials are used as filler in elastomer compositions, then manufacturing cost is reduced, but mechanical properties are diminished
Solution Approach 1:
The patent applies parameter changes by modifying the chemical structure of reclaimed elastomer through devulcanization, transforming cross-linked vulcanized rubber into a state with broken cross-links that enables reactive bonding with virgin elastomer matrices, thereby improving mechanical properties while maintaining cost benefits
Solution Approach 2:
The patent creates composite materials by combining devulcanized reclaimed elastomer with virgin elastomer matrices, forming a hybrid composition that leverages the cost advantage of reclaimed material while achieving the mechanical performance of virgin materials through synergistic interaction
2Adaptability or versatility
If particle size of reclaimed elastomer is reduced to increase surface area, then reactivity with virgin matrix is improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the chemical state parameter of reclaimed elastomer through devulcanization, breaking cross-links to create reactive sites that enhance interfacial bonding without requiring particle size reduction, thus maintaining cost effectiveness while improving reactivity
Solution Approach 2:
The patent replaces the mechanical approach (particle size reduction) with a chemical approach (devulcanization), substituting physical refinement with chemical modification to achieve reactivity enhancement at lower cost
3Adaptability or versatility
If devulcanization is performed using chemical additives under shear stresses, then functionalization is achieved, but process complexity increases
Solution Approach 1:
The patent applies self-service by using the reclaimed elastomer's own cross-linked structure as the target for modification, where devulcanization agents selectively break cross-links within the material itself, enabling functionalization without requiring complex external processing equipment
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The functionalized reclaimed elastomer materials exhibit improved tensile strength and elongation properties, particularly when the particle size is reduced, demonstrating that smaller mesh size functionalized micronized rubber powder (MRP) outperforms larger mesh size ground tire rubber (GTR) in elastomer compositions, potentially enabling their use in high-performance applications.
Implementation Method 1
subjecting particles of the reclaimed elastomer material to shear at temperatures less than 100 °C
Implementation Method 2
using a two-roll mill process with a modifier like urea or urea derivatives to break cross-links
Implementation Method 3
using a two-roll mill process with a modifier like urea or urea derivatives to break cross-links
Data Source
Figure 1
AI summary
A method of functionalizing reclaimed elastomer material is described. The method involves subjecting particles of the reclaimed elastomer material to shear at temperatures less than 100 C such that inter-chain bonds of the reclaimed elastomer material are cleaved wherein the particles of the reclaimed elastomer material have a size of 60 mesh or smaller. The reclaimed elastomer material can be subjected to shear in the presence of a modifier which selectively promotes the cleavage of inter-chain bonds in the reclaimed elastomer material. A functionalized reclaimed elastomer material made by a method as described above and an elastomer compound which comprises the functionalized reclaimed elastomer material are also described.