Method for making free-flowing, melt-coated rubber pellets

Claim 2

A continuous method for making at least one melt-coated pellet of material comprising: mixing coating material with at least one stream of carrier gas to form at least one coating stream, the carrier gas having a temperature below the melting point of the coating material; contacting at least one pellet of macromolecular material having a glass transition temperature and melting point temperature in the elastomeric range with the coating stream, said pellet having a temperature at or above its melting point and above the melting point of the coating material, so as to form at least one layer of substantially melted coating on the pellet; and cooling the resulting melted coating to a temperature below the melting point of the coating material; whereby at least one melt-coated pellet is made.

Claim 3

A method according to claim 1, wherein the pellet is introduced into the coating stream in such a manner as to create at least one zone of interference in which the coating material coats the pellet.

Claim 4

A method according to claim 2, wherein the pellet is caused to flow co-currently with the carrier gas from the zone of interference to a downstream zone.

Claim 5

A method according to claim 2 or 3, wherein the coating material is mixed with the carrier gas before the pellet is contacted with the coating stream.

Claim 6

A method according to claim 4, wherein the coating material is solid, particulate coating material entrained in the carrier gas.

Claim 7

A method according to claim 5, wherein the coating material has a melting point temperature of about 150° F. to 450° F.

Claim 8

A method according to claim 6, wherein on a weight basis the melt-coating is about 1% to 15% of the pellet.

Claim 9

A method according to claim 7, wherein on a weight basis the melt-coating is about 1% to 10% of the pellet.

Claim 10

A method according to claim 8, wherein the melt-coating has an average thickness of about 0.00025 to 0.05 inch.

Claim 11

A method according to claim 9, wherein the ratio of the average diameter of the pellet to the average diameter of the coating particles is at least about 10:1.

Claim 12

A method according to claim 10, wherein the size of the pellet is about 1/32 to 1 inch.

Claim 13

A method according to claim 11, wherein the carrier gas is air.

Claim 14

A method according to claim 12, wherein the pellet is EPDM rubber and the coating is polyethylene.

Claim 15

A method according to claim 2 or 3 wherein said melted coating is substantially continuous.

Claim 16

A method according to claim 1, wherein the velocity of the coating stream is about 75 to 200 feet per second.

Claim 17

A method according to claim 15, wherein the velocity of the coating stream is about 100 to 175 feet per second.

Claim 18

A method according to claim 15 or 16, wherein the ratio of the average diameter of the pellet to the average diameter of the coating particles is at least about 10:1.

Claim 19

A method according to claim 17, wherein the ratio is at least about 25:1.

Claim 20

A method according to claim 18, wherein the ratio is at least about 100:1.

Claim 21

A method according to claim 19, wherein the pellet is EPDM and the coating material is polyethylene.

Claim 22

A method according to claim 15 wherein said melted coating is substantially continuous.

Claim 23

A method according to claim 15, wherein the pellet is introduced into the coating stream at substantially zero velocity in the direction of flow of the coating stream.

Claim 24

A method according to claim 15, wherein the pellet is introduced into the coating stream at some negative velocity in the direction of flow of the coating stream.

Claim 25

A continuous method for making at least one melt-coated pellet of material comprising: mixing coating material with at least one stream of carrier gas to form at least one coating stream, wherein the carrier gas has a temperature below the melting point of the coating material and the coating stream has a velocity of about 75 to 200 feet per second; introducing at least one tumbling pellet of macromolecular material, said pellet having a glass transition temperature and melting point temperature in the elastomeric range and a temperature above the melting point temperature of both the coating material and the pellet, into the coating stream at substantially zero or some negative velocity in the direction of flow of the coating stream so as to create at least one zone of interference in which at least one layer of substantially melted coating material is formed on the pellet, and cooling the resulting melted coating to a temperature below the melting point of the coating material.

Claim 26

A continuous method for making at least one melt-coated pellet of material comprising: mixing coating material with at least one stream of carrier gas to form at least one coating stream, wherein the carrier gas has a temperature below the melting point of the coating material and the coating stream has a velocity of about 75 to 200 feet per second; introducing at least one tumbling pellet of macromolecular material, said pellet having a glass transition temperature and melting point temperature in the elastomeric range and a temperature above the melting point temperature of both the coating material and the pellet, into the coating stream at substantially zero or some negative velocity in the direction of flow of the coating stream so as to create at least one zone of interference in which at least one layer of substantially melted coating material is formed on the pellet, and cooling the resulting melted coating to a temperature below the melting point of the coating material.