Coprecipitation process

Claim 2

A process for improving the clarity of the serum produced during coprecipitation of a rubber or plastic compounding chemical and a binder, comprising (a) intimately mixing at least one finely divided rubber or plastic compounding chemical, wherein substantially all of the particles thereof are at least about 0.05 micron in size, with a film-forming binder emulsion comprising a latex of a rubber or plastic polymer in the presence of an amount of water which permits intimate mixture thereof, wherein no compounding chemical used is a reinforcing agent or diluent for rubber or plastic stock,

Claim 3

(b) adding a stoichiometric excess of a coagulating agent during further intimate mixing of the chemical and the binder emulsion to cause complete coagulation thereof, and (c) physically separating the substantially clear serum produced upon coagulation from the homogeneous, essentially non-tacky, dustless, friable particles of predispersed chemical which comprise from about 80 to about 99.5 percent by weight of said chemical and from about 0.5 to about 20 percent by weight of said binder.

Claim 4

(b) adding a stoichiometric excess of a coagulating agent during further intimate mixing of the chemical and the binder emulsion to cause complete coagulation thereof, and (c) physically separating the substantially clear serum produced upon coagulation from the homogeneous, essentially non-tacky, dustless, friable particles of predispersed chemical which comprise from about 80 to about 99.5 percent by weight of said chemical and from about 0.5 to about 20 percent by weight of said binder.

Claim 5

The process of claim 1 wherein the finely divided chemical is in dry powder form.

Claim 6

The process of claim 2 wherein the chemical in finely divided powder form is intimately mixed with water to deagglomerate and wet the chemical prior to the intimate mixing of the chemical with the binder emulsion.

Claim 7

The process of claim 1 wherein the finely divided chemical is in the form of a wet filtercake.

Claim 8

The process of claim 1 wherein the finely divided chemical is formed by wet grinding coarse chemical.

Claim 9

The process of claim 1 wherein the compounding chemical has a particle size less than about 250 microns.

Claim 10

The process of claim 6 wherein the compounding chemical has a particle size less than about 50 microns.

Claim 11

The process of claim 1 wherein the polymer latex is natural rubber latex.

Claim 12

The process of claim 1 wherein the polymer latex was prepared by an emulsion polymerization process.

Claim 13

The process of claim 9 wherein the polymer latex is selected from the group consisting of latices of polybutadiene; copolymers of butadiene and one or more comonomers including styrene, acrylonitrile, methylmethacrylate, vinylpyridine, and derivatives of butadiene and a carboxylic acid; polymers of substituted butadiene; copolymers of vinyl acetate and ethylene; poly(vinyl chloride); poly(vinyl chloride-vinylidene chloride); poly(vinylidene chloride); and acrylonitrile-butadiene-styrene copolymer.

Claim 14

The process of claim 1 wherein the polymer was prepared by a solution polymerization process and subsequently emulsified to form the latex.

Claim 15

The process of claim 11 wherein the polymer latex is selected from the group consisting of latices of EPDM, EPR, oxidized polyethylene, polyisobutylene, butyl rubber, polyisoprene, block copolymers of styrene and butadiene, and thermoplastic rubbers.

Claim 16

A process for improving the clarity of the serum produced during coprecipitation of a rubber or plastic compounding chemical and a binder, comprising (a) intimately mixing at least one finely divided rubber or plastic compounding chemical wherein substantially all of the particles thereof are at least about 0.05 micron in size, with a film-forming binder emulsion comprising a latex of a rubber or plastic polymer and an emulsion of a plasticizer for the polymer in the presence of an amount of water which permits intimate mixture thereof, wherein no compounding chemical is a reinforcing agent or diluent for rubber or plastic stock, (b) adding a stoichiometric excess of a coagulating agent during further intimate mixing of the chemical and the binder emulsion to cause complete coagulation thereof, and (c) physically separating the substantially clear serum produced upon coagulation from the homogeneous, essentially non-tacky, dustless, friable particles of predispersed chemical which comprise from about 80 to 99.5 percent by weight of said chemical and from about 0.5 to about 20 percent by weight of said binder.

Claim 17

A process for improving the clarity of the serum produced during coprecipitation of a rubber or plastic compounding chemical and a binder, comprising (a) intimately mixing at least one finely divided rubber or plastic compounding chemical wherein substantially all of the particles thereof are at least about 0.05 micron in size, with a film-forming binder emulsion comprising a latex of a rubber or plastic polymer and an emulsion of a plasticizer for the polymer in the presence of an amount of water which permits intimate mixture thereof, wherein no compounding chemical is a reinforcing agent or diluent for rubber or plastic stock, (b) adding a stoichiometric excess of a coagulating agent during further intimate mixing of the chemical and the binder emulsion to cause complete coagulation thereof, and (c) physically separating the substantially clear serum produced upon coagulation from the homogeneous, essentially non-tacky, dustless, friable particles of predispersed chemical which comprise from about 80 to 99.5 percent by weight of said chemical and from about 0.5 to about 20 percent by weight of said binder.

Claim 18

The process of claim 13 wherein the finely divided chemical is in dry powder form.

Claim 19

The process of claim 14 wherein the compounding chemical in finely divided powder form is intimately mixed with water to deagglomerate and wet the chemical prior to the intimate mixing of the chemical with the binder emulsion.

Claim 20

The process of claim 13 wherein the finely divided chemical is in the form of a wet filtercake.

Claim 21

The process of claim 13 wherein the finely divided chemical is formed by wet grinding coarse chemical.

Claim 22

The process of claim 13 wherein the compounding chemical has a particle size less than about 250 microns.

Claim 23

The process of claim 18 wherein the compounding chemical has a particle size less than about 50 microns.

Claim 24

The process of claim 13 wherein the polymer latex is natural rubber latex.

Claim 25

The process of claim 13 wherein the polymer latex was prepared by an emulsion polymerization process.

Claim 26

The process of claim 21 wherein the polymer latex is selected from the group consisting of latices of polybutadiene; copolymers of butadiene and one or more comonomers including styrene, acrylonitrile, methylmethacrylate, vinylpyridine, and derivatives of butadiene and a carboxylic acid; polymers of substituted butadiene; copolymers of vinyl acetate and ethylene; poly(vinyl chloride); poly(vinyl chloride-vinylidene chloride); poly(vinylidene chloride); and acrylonitrile-butadiene-styrene copolymer.

Claim 27

The process of claim 13 wherein the polymer was prepared by a solution polymerization process and subsequently emulsified to form the latex.

Claim 28

The process of claim 23 wherein the polymer latex is selected from the group consisting of latices of EPDM, EPR, oxidized polyethylene, polyisobutylene, butyl, rubber, polyisoprene, block copolymers of styrene and butadiene, and thermoplastic rubbers.

Claim 29

The process of claim 13 wherein the binder comprises less than about 98 percent by weight of the plasticizer.

Claim 30

A process for improving the clarity of the serum produced during preparation and coprecipitation of a rubber or plastic compounding chemical and a binder, comprising, (a) intimately mixing a solution of a water soluble salt containing the organic portion of the desired compounding chemical with a film-forming binder emulsion comprising a latex of a rubber or plastic polymer in the presence of an amount of water which permits intimate mixture thereof, (b) during further intimate mixing, adding a solution of a water soluble salt containing the metal cation desired in the compounding chemical, wherein the amount of metal cation present is in excess of that required to quantitatively react with the soluble salt containing the organic portion of the desired compounding chemical to form the desired compounding chemical and to coagulate the binder emulsion, thereby forming the desired compounding chemical and coprecipitating it with the binder substantially simultaneously, and wherein the compounding chemical prepared is not a reinforcing agent or diluent for rubber or plastic stock, and (c) physically separating the substantially clear serum produced upon coagulation from the homogeneous, essentially non-tacky, dustless, friable particles of predispersed chemical which comprise from about 80 to about 99.5 percent by weight of said chemical and from about 0.5 to about 20 percent by weight of said binder.

Claim 31

A process for improving the clarity of the serum produced during preparation and coprecipitation of a rubber or plastic compounding chemical and a binder, comprising, (a) intimately mixing a solution of a water soluble salt containing the organic portion of the desired compounding chemical with a film-forming binder emulsion comprising a latex of a rubber or plastic polymer in the presence of an amount of water which permits intimate mixture thereof, (b) during further intimate mixing, adding a solution of a water soluble salt containing the metal cation desired in the compounding chemical, wherein the amount of metal cation present is in excess of that required to quantitatively react with the soluble salt containing the organic portion of the desired compounding chemical to form the desired compounding chemical and to coagulate the binder emulsion, thereby forming the desired compounding chemical and coprecipitating it with the binder substantially simultaneously, and wherein the compounding chemical prepared is not a reinforcing agent or diluent for rubber or plastic stock, and (c) physically separating the substantially clear serum produced upon coagulation from the homogeneous, essentially non-tacky, dustless, friable particles of predispersed chemical which comprise from about 80 to about 99.5 percent by weight of said chemical and from about 0.5 to about 20 percent by weight of said binder.

Claim 32

The process of claim 26 wherein the binder emulsion further comprises an emulsion of a plasticizer for the polymer.

Claim 33

The process of claim 27 wherein the binder comprises less than about 98 percent by weight of the plasticizer.

Claim 34

The process of claim 26 wherein the polymer latex is natural rubber latex.

Claim 35

The process of claim 26 wherein the polymer latex was prepared by an emulsion polymerization process.

Claim 36

The process of claim 30 wherein the polymer latex is selected from the group consisting of latices of polybutadiene; copolymers of butadiene and one or more comonomers including styrene, acrylonitrile, methylmethacrylate, vinylpyridine, and derivatives of butadiene and a carboxylic acid; polymers of substituted butadiene; copolymers of vinyl acetate and ethylene; poly(vinyl chloride); poly(vinyl chloride-vinylidene chloride); poly(vinylidene chloride); and acrylonitrile-butadiene-styrene copolymer.

Claim 37

The process of claim 26 wherein the polymer was prepared by a solution polymerization process and subsequently emulsified to form the latex.

Claim 38

The process of claim 32 wherein the polymer latex is selected from the group consisting of latices of EPDM, EPR, oxidized polyethylene, polyisobutylene, butyl rubber, polyisoprene, block copolymers of styrene and butadiene, and thermoplastic rubbers.

Claim 39

The process of claim 26 wherein the compounding chemical is selected from the group consisting of the dithiocarbamates, the thiazoles, and the xanthates.

Claim 40

A product comprising (i) substantially clear serum and (ii) homogeneous, essentially non-tacky, dustless, friable particles of predispersed rubber or plastic compounding chemical which comprise from about 80 to about 99.5 percent by weight of said chemical and from about 0.5 to about 20 percent by weight of a binder, said product prepared in accordance with a coprecipitation process comprising, (a) intimately mixing at least one finely divided rubber or plastic compounding chemical wherein substantially all of the particles thereof are at least about 0.05 micron in size with a film-forming binder emulsion comprising a latex of a rubber or plastic polymer in the presence of an amount of water which permits intimate mixture thereof, wherein no compounding chemical used is a reinforcing agent or diluent for rubber or plastic stock, and (b) adding a stoichiometric excess of a coagulating agent during further intimate mixing of the chemical and the binder emulsion to cause complete coagulation thereof.

Claim 41

A product comprising (i) substantially clear serum and (ii) homogeneous, essentially non-tacky, dustless, friable particles of predispersed rubber or plastic compounding chemical which comprise from about 80 to about 99.5 percent by weight of said chemical and from about 0.5 to about 20 percent by weight of a binder, said product prepared in accordance with a coprecipitation process comprising, (a) intimately mixing at least one finely divided rubber or plastic compounding chemical wherein substantially all of the particles thereof are at least about 0.05 micron in size with a film-forming binder emulsion comprising a latex of a rubber or plastic polymer in the presence of an amount of water which permits intimate mixture thereof, wherein no compounding chemical used is a reinforcing agent or diluent for rubber or plastic stock, and (b) adding a stoichiometric excess of a coagulating agent during further intimate mixing of the chemical and the binder emulsion to cause complete coagulation thereof.

Claim 42

The product of claim 35 wherein the fully divided chemical is in dry powder form.

Claim 43

The product of claim 36 wherein the chemical in finely divided powder form is intimately mixed with water to deagglomerate and wet the chemical prior to the intimate mixing of the chemical with the polymer latex.

Claim 44

The product of claim 35 wherein the finely divided chemical is in the form of a wet filtercake.

Claim 45

The product of claim 35 wherein the finely divided chemical is formed by wet grinding coarse chemical.

Claim 46

The product of claim 35 wherein the compounding chemical has a particle size less than about 250 microns.

Claim 47

The product of claim 40 wherein the compounding chemical has a particle size less than about 50 microns.

Claim 48

The product of claim 35 wherein the polymer latex is natural rubber latex.

Claim 49

The product of claim 35 wherein the polymer latex was prepared by an emulsion polymerization process.

Claim 50

The product of claim 43 wherein the polymer latex is selected from the group consisting of latices of polybutadiene; copolymers of butadiene and one or more comonomers including styrene, acrylonitrile, methylmethacrylate, vinylpyridine, and derivatives of butadiene and a carboxylic acid; polymers of substituted butadiene; copolymers of vinyl acetate and ethylene; poly(vinyl chloride); poly(vinyl chloride-vinylidene chloride); poly(vinylidene chloride); and acrylonitrile-butadiene-styrene copolymer.

Claim 51

The product of claim 35 wherein the polymer was prepared by a solution polymerization process and subsequently emulsified to form the latex.

Claim 52

The product of claim 45 wherein the polymer latex is selected from the group consisting of latices of EPDM, EPR, oxidized polyethylene, polyisobutylene, butyl rubber, polyisoprene, block copolymers of styrene and butadiene, and thermoplastic rubbers.

Claim 53

A product comprising (i) substantially clear serum and (ii) homogeneous, essentially non-tacky, dustless, friable particles of predispersed rubber or plastic compounding chemical which comprise from about 80 to about 99.5 percent by weight of said chemical and from about 0.5 to about 20 percent by weight of a binder, said product prepared in accordance with a coprecipitation process comprising, (a) intimately mixing at least one finely divided rubber or plastic compounding chemical wherein substantially all of the particles thereof are at least about 0.05 micron in size with a film-forming binder emulsion comprising a latex of rubber or plastic polymer and an emulsion of a plasticizer for the polymer in the presence of an amount of water which permits intimate mixture thereof, wherein no compounding chemical is a reinforcing agent or diluent for rubber or plastic stock, and (b) adding a stoichiometric excess of a coagulating agent during further intimate mixing of the chemical and the binder emulsion to cause complete coagulation thereof.

Claim 54

A product comprising (i) substantially clear serum and (ii) homogeneous, essentially non-tacky, dustless, friable particles of predispersed rubber or plastic compounding chemical which comprise from about 80 to about 99.5 percent by weight of said chemical and from about 0.5 to about 20 percent by weight of a binder, said product prepared in accordance with a coprecipitation process comprising, (a) intimately mixing at least one finely divided rubber or plastic compounding chemical wherein substantially all of the particles thereof are at least about 0.05 micron in size with a film-forming binder emulsion comprising a latex of rubber or plastic polymer and an emulsion of a plasticizer for the polymer in the presence of an amount of water which permits intimate mixture thereof, wherein no compounding chemical is a reinforcing agent or diluent for rubber or plastic stock, and (b) adding a stoichiometric excess of a coagulating agent during further intimate mixing of the chemical and the binder emulsion to cause complete coagulation thereof.

Claim 55

The product of claim 47 wherein the finely divided chemical is in dry powder form.

Claim 56

The product of claim 48 wherein the compounding chemical in finely divided powder form is intimately mixed with water to deagglomerate and wet the chemical prior to the intimate mixing of the chemical with the binder emulsion.

Claim 57

The product of claim 47 wherein the finely divided chemical is in the form of a wet filtercake.

Claim 58

The product of claim 47 wherein the finely divided chemical is formed by wet grinding coarse chemical.

Claim 59

The product of claim 47 wherein the compounding chemical has a particle size less than about 250 microns.

Claim 60

The product of claim 52 wherein the compounding chemical has a particle size less than about 50 microns.

Claim 61

The product of claim 47 wherein the polymer latex is natural rubber latex.

Claim 62

The product of claim 47 wherein the polymer latex was prepared by an emulsion polymerization process.

Claim 63

The product of claim 55 wherein the polymer latex is selected from the group consisting of latices of polybutadiene; copolymers of butadiene and one or more comonomers including styrene, acrylonitrile, methylmethacrylate, vinylpyridine, and derivatives of butadiene and a carboxylic acid; polymers of substituted butadiene; copolymers of vinyl acetate and ethylene; poly(vinyl chloride); poly(vinyl chloride-vinylidene chloride); poly(vinylidene chloride); and acrylonitrile-butadiene-styrene copolymer.

Claim 64

The product of claim 47 wherein the polymer was prepared by a solution polymerization process and subsequently emulsified to form the latex.

Claim 65

The product of claim 57 wherein the polymer latex is selected from the group consisting of latices of EPDM, EPR, oxidized polyethylene, polyisobutylene, butyl rubber, polyisoprene, block copolymers of styrene and butadiene and thermoplastic rubbers.

Claim 66

The product of claim 47 wherein the binder comprises less than about 98 percent by weight of the plasticizer.

Claim 67

Associatively formed products of a coprecipitation process comprising (i) substantially clear serum and (ii) homogeneous, essentially non-tacky, dustless, friable particles of predispersed rubber or plastic compounding chemical which comprise from about 80 to about 99.5 percent by weight of said chemical and from about 0.5 to about 20 percent by weight of a binder comprising a rubber or plastic polymer, wherein substantially all of the particles of the compounding chemical are at least about 0.05 micron in size and no compounding chemical used is a reinforcing agent or diluent for rubber or plastic stock.

Claim 68

Associatively formed products of a coprecipitation process comprising (i) substantially clear serum and (ii) homogeneous, essentially non-tacky, dustless, friable particles of predispersed rubber or plastic compounding chemical which comprise from about 80 to about 99.5 percent by weight of said chemical and from about 0.5 to about 20 percent by weight of a binder comprising a rubber or plastic polymer, wherein substantially all of the particles of the compounding chemical are at least about 0.05 micron in size and no compounding chemical used is a reinforcing agent or diluent for rubber or plastic stock.

Claim 69

The products of claim 60 wherein the compounding chemical has a particle size less than about 250 microns.

Claim 70

The products of claim 61 wherein the compounding chemical has a particle size less than about 50 microns.

Claim 71

The products of claim 60 wherein the polymer is natural rubber.

Claim 72

The products of claim 60 wherein the polymer is selected from the group consisting of polybutadiene; copolymers of butadiene and one or more comonomers including styrene, acrylonitrile, methylmethacrylate, vinylpyridine, and derivatives of butadiene and a carboxylic acid; polymers of substituted butadiene; copolymers of vinyl acetate and ethylene; poly(vinyl chloride); poly(vinyl chloride-vinylidene chloride); poly(vinylidene chloride); and acrylonitrile-butadiene-styrene copolymer.

Claim 73

The products of claim 60 wherein the polymer is selected from the group consisting of EPDM, EPR, oxidized polyethylene, polyisobutylene, butyl rubber, polyisoprene, block copolymers of styrene and butadiene, and thermoplastic rubber.

Claim 74

The products of claim 60 wherein the binder further comprises a plasticizer for the polymer.