DEVULCANIZA HON OF RUBBER AND OTHER ELASTOMERS

Cross-Reference to Related Applications

This application is based on and claims priority to U.S. Non-Provisional Application Serial No. 12/690,608 filed on January 20, 2010, which is hereby incorporated herein by reference.

Field of the Invention

The present invention relates to the recycling of vulcanized elastomers, such as vulcanized rubber found in tires, involving the use of an alternating dielectric radio frequency field to devulcanize the elastomers.

Description of Related Art

Millions of used tires, hoses, belts, and other vulcanized rubber products arc discarded annually after they have been worn-out during their limited service life. These used vulcanized rubber products are typically hauled to a dump because there is very little use for them after they have served their original intended purpose. A limited number of used tires are utilized in building retaining walls, as guards for protecting boats and similar things where resistance to weathering is desirable. Efforts to reclaim scrap vulcanized rubber have primarily included a physical shearing process which is suitable for a rubber which can be mixed with asphalt, forming asphalt rubber. However, a far greater number of tires, hoses, and belts are simply discarded.

During the vulcanization process of rubber, accelerators, promoters, and/or initiators, are used to form large numbers of sulfiir crosslinks. After vulcanization, the crosslinked rubber becomes thermosct and cannot be reformed into other products. Thus, vulcanized rubber products generally cannot be simply melted and recycled into new products. The sul fur crosslinks which are present in used vulcanized rubber, such as tire rubber, are deleterious in a subsequent curing process which uses used vulcanized rubber as a component in a new polymer mixture. Formulations of tire rubber which use more than minor amounts of vulcanized rubber result in a brittle cured end product unsuitable for many uses such as automobile or truck tires.

In light of the foregoing, various techniques for devulcanizing rubber have been developed. For example, in one devulcanization process, vulcanized rubber is placed in an organic solvent to recover various polymerized fractions as taught in Butcher, Jr. et al., U.S. Patent No. 5,438,078. Platz, U.S. Patent No. 5,264.640 teaches taking scrap rubber from used tires and regenerating the monomeric chemicals which are subsequently recovered. This method uses gaseous ozone to break down the crosslinked structure of the rubber followed by thermal depolymerization in a reaction chamber. Platz et al., U.S. Patent No. 5,369,215 teaches a similar process in which used tire material may be depolymerized under elevated temperatures and at a reduced pressure to recover the monomeric compounds. Myers et al., U.S. Patent No. 5,602, 1 6 discloses a process for devulcanizing rubber by desulfurization. comprising the steps of: contacting vulcanized crumb rubber with a solvent and an alkali metal to form a reaction mixture, heating the reaction mixture in the absence of oxygen and with mixing to a temperature sufficient to cause the alkali metal to react with sulfur in the crumb rubber, and maintaining the temperature below that at which thermal cracking of the rubber occurs, thereby devulcanizing the crumb rubber. Hunt et al., U.S. Patent No. 5,891 ,926 is directed to a devulcanization process for rubber in which elevated temperatures and pressures are used to partially devulcanize the rubber. Thereafter, a solvent 2-butanol is used to extract the devulcanized rubber from the non-rubber and/or solids component.

Novotny et al., U.S. Patent No. 4,104,205 discloses a technique for devulcanizing sulfur-vulcanized elastomer containing polar groups which comprises applying a controlled dose of microwave energy of between 915 MHz and 2450 MHz and between 41 and 177 watt-hours per pound in an amount sufficient to sever substantially all carbon-sulfur and sulfur-sulfur bonds and insufficient to sever significant amounts of carbon-carbon bonds. Other patents directed to microwave techniques include Lai et al. U.S. Patent No. 4,440,488; Hayashi et al., U.S. Patent No. 4,469,817; Picker. U.S. Patent No. 4,665,101 ; and Wicks et al., U.S. Patent No. 6,420,457. In general, the application of microwave energy results in uneven heating of the elastomer. As such, the degree to which the elastomeric particles are devulcanized vary within the rubber particle, which is typically most evidenced by different surface and interior properties.

Isayev et al., U.S. Patent No. 5,284,625 discloses a continuous ultrasonic method for breaking the carbon-sulfur, sulfur-sulfur and, if desired, the carbon-carbon bonds in a vulcanized elastomer. Through the application of certain levels of ultrasonic energy ( 15 kHz to 50 kHz) in the presence of pressure and optionally heat, it is reported that vulcanized rubber can be broken down. Using this process, the rubber becomes soft, thereby enabling it to be reprocessed and reshaped in a manner similar to that employed with previously uncured elastomers. Other patents directed to ultrasonic devulcanization techniques include Isayev. U.S. Patent No. 5,258.414 and Roberson et al.. U.S. Patent No. 6,095,440.

Despite the various devulcanization processes known the art, there remains a need to develop improved devulcanization techniques, especially those that are capable of devulcanizing the rubber particles in a relatively uniform manner.

Brief Summary of the Invention

The present invention is directed to a process for devulcanizing crosslinked elastomer particles. The process comprises ( 1 ) providing a composition comprising vulcanized crosslinked elastomeric articles in a devulcanization apparatus; and (2 ) applying an alternating radio frequency dielectric field to the composition comprising the vulcanized crosslinked elastomer particles (with optional fresh unvulcanized rubber), the alternating radio frequency dielectric field having a frequency and voltage sufficient to devulcanize the crosslinked elastomer particles. In one aspect, the frequency of the alternating radio frequency dielectric field is about 1 MHz to 100 MHz, and wherein the voltage of the alternating radio frequency dielectric field is about 1000 to 1 0,000 V. In another aspect, the crosslinked elastomer particles comprises a polar vulcanized rubber material, in still another aspect, the crosslinked elastomer particles have a particle size of 6 to 400 mesh. In still another aspect, the fresh unvulcanized rubber comprises at least 10 wt% of the composition.

In one aspect, the composition is placed in a mold which resides between a first electrode (e.g. , lop electrode) and a second electrode (e.g. , bottom electrode). The alternating radio frequency dielectric field is generated between the first and second electrodes. The process may be operated in batch mode or the composition may be continuously fed between the first top electrode and the second bottom electrode. In another aspect, the top electrode is a high voltage electrode having a voltage between 1000 and 10,000 V.

In yet another aspect, the alternating radio frequency dielectric field is generated between a plural ity of top transverse electrode rods and a plurality of bottom transverse electrode rods. The process may be operated in batch mode or the composition may be continuously fed between the top transverse electrode rods and the bottom transverse electrode rods. Exemplary conveying devices include a conveyor and roller assembly.

In yet another aspect, the present invention is directed to a process for forming a vulcanized elastomer composition. The process comprises ( 1 ) applying an alternating radio frequency dielectric field to a first composition comprising vulcanized crosslinked elastomer particles, alternating radio frequency dielectric field having a frequency and voltage sufficient to devulcanize the crosslinked elastomer particles lo form a second composition comprising devulcanized elastomer particles; and (2) adding a crosslinking agent to the second composition comprising the devulcanized elastomer particles; and (3) vulcanizing the second composition having the crosslinking agent to form the vulcanized elastomer composition. In one aspect, the the frequency of the alternating radio frequency dielectric field is about 1 MHz to 1 00 MHz, and wherein the voltage of the alternating radio frequency dielectric field is about 1000 to 10.000 V.

The first composition may comprise a vulcanized rubber, such as one having a particle size of 6 to 400 mesh. The first composition may vulcanize rubber particles and optionally fresh unvulcanized rubber. In one aspect, the fresh unvulcanized rubber comprises at least 10 wl% of the first composition. In still another aspect, the present invention comprises the step of adding fresh unvulcanized rubber to the second composition prior to the vulcanizing step. In one aspect, the fresh unvulcanized rubber may comprise at least 10 wt% of the second composition. In still another aspect, the process comprises the step of adding a filler and/or or vulcanization accelerator to the second composition prior to the vulcanizing step. Suitable crosslinking agents include sulfur or a sulfur donor. In yet another aspect, the vulcanizing step comprises heating the second composition comprising the crosslinker and the devulcanized elastomer particles.

Additional aspects of the invention, together with the advantages and novel features appurtenant thereto, will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the fol lowing, or may be learned from the practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumental ities and combinations particularly pointed out in the appended claims.

Brief Description of the Drawings

FIG. 1 is a process flow diagram il lustrating how vulcanized rubber (or other vulcanized elastomers) may be devulcanized in accordance with the present invention and then subsequently revulcanized into useful end products.

FIG. 2 is a devulcanization apparatus which employs an alternating radio frequency dielectric field in accordance with a first embodiment of the present invention.

FIG. 3 shows a signal generated by the generator operable to generate a dielectric field, in which the signal is substantially a sinusoid having a wavelength λ. FIG. 4 il lustrates a preferred electrode configuration for generating the alternating radio frequency dielectric field in accordance with the present invention. The electrode configuration is shown without the other components of the devulcanization apparatus.

F IG. 5 shows the peak of the sinusoid of FIG. 3, with point X (FIG. 2) and points Λ. B, C, D, E, F, G, and H (FIG. 4) superimposed thereon in order to il l ustrate the differences between the configurations of top electrode 12 (FIG. 2) and top electrode 22 (FIG. 4).

FIG. 6 is a devulcanization apparatus which employs an alternating radio frequency dielectric field in accordance with a second embodiment of the present invention.

FIG. 7 is a devulcanization apparatus which employs an alternating radio frequency dielectric field in accordance with a third embodiment of the present invention. Detailed Description of Preferred Embodiment

The present invention is directed to a process for devulcanizing crossiinked vulcanized elastomers by applying an alternating radio frequency dielectric field to the vulcanized elastomer. ^' I~he alternating radio frequency dielectric field may be applied to a wide range of crossiinked vulcanized thermoset elastomers, such as those polymeric networks found in many thermosets. Without being limited to the enumerated examples, these vulcanized elastomers include polyurethanes. epoxy/phenolic resins, epoxy resins, saturated polyester resins, unsaturated polyester resins, phenolic/formaldehyde resins, rubber, and combinations thereof. Once the elastomer has been devulcanized, it can be revulcanized into additional useful end products. The elastomer may be combined with other materials during the devulcanization process. For example, it is contemplated that a whole shoe may be ground, shredded, or otherwise cut into small particles, and then the rubber from the shoe may be devulcanized in accordance with the present invention.

The term "vulcanized" refers to a three-dimensional crossiinked structure between the elastomer (e.g. , rubber) molecules. Thus, the term "vulcanized rubber" encompasses rubbers having a three-dimensional crossiinked structure between rubber molecules. The introduction of the crossiinked structure may be performed by various crosslinking methods known to those skilled in the art, such as those involving sul fur vulcanization, thiuram cure, peroxide vulcanization, and the like.

The term "devulcanized" is used to indicate that certain surface and bulk properties of the crossiinked vulcanized elastomer (e.g. , vulcanized rubber) have been chemically altered by the application of the alternating radio frequency dielectric Held in accordance with the present invention. In general, the number of mono, di, and polysul l des which formed polymer crosslinks during the initial vulcanization process are reduced by the alternating radio frequency dielectric field devulcanizatiori process. As such, the elastomer (e.g. , rubber) is referred to here as "devulcanized" though it is understood that some crosslinking may remain in the end "devulcanized" product.

The term "fresh" or "virgin" or "unvulcanized" is used to indicate that the elastomer (e.g. , rubber) has not been vulcanized.

In one exemplary embodiment, the vulcanized elastomer that is to be devulcanized using an alternating radio frequency dielectric field in accordance with the present invention is a rubber elastomer. Thus, the present invention is directed to a process for devulcanizing rubber by applying an alternating radio frequency dielectric field to the vulcanized rubber. An overview of the process ^' 1 is illustrated in FIG. 1 . In general , a vulcanized rubber composition 2, such as that found in tires, is ground or milled to form a "crumb rubber" composition 3 having a reduced particle size. The crumb rubber composition 3 is then optionally combined with fresh or virgin unvulcanized rubber 4 and then devulcanized by applying an alternating radio frequency dielectric field in accordance with the present invention. The resulting devulcanized rubber composition 5 may optionally be combined with additional fresh or virgin unvulcanized rubber 4 and then revulcanized to form an end product.

The vulcanized rubber composition 2, or more generally the crosslinked vulcanized elastomer, to be devulcanized by applying an alternating radio frequency dielectric field in accordance with the present invention may comprise cither polar or non- polar or low-polar rubbers. That is. the vulcanized rubber may be comprised of rubbers having inherent polarity, for example, polychloroprene rubber, nitrile rubber, nitri le rubber- poly(vinyl chloride) blends [ for example, 30 percent by weight maximum poly(vinyl chloride), and typically about 20 percent polyvinyl chloride) by weight], bromobutyl rubber, or chlorobutyl rubber. Nearly all commercial tires are comprised of polar rubbers. Vulcanized non-polar or low-polar rubbers (for example, polyolefin rubbers (e.g. , ethylene- propylene rubbers, butadiene rubbers, styrene-butadiene rubbers), tluorocarbon rubbers like Teflon®, and silicone rubbers may be devulcanized in accordance with the present invention if the polarity has been introduced as the result of some other material introduced into the rubber composition (for example, carbon black ). Thus, various additives may be added to the rubber composition in order to improve or tune the polarity of the rubber composition as desired. The use of additives is generally described in Marc, U.S. Patent Application No. 2006/0012083, which is incorporated by reference. Other examples of specific vulcanized rubbers which may be devulcanized by the alternating radio frequency dielectric field process includes polyalkenylenes, synthetic elastomers made from monomer of conjugated dienes having from 4 to 1 0 carbon atoms or interpolymers of said dienes ( 1 ) among themsel ves, or (2) with monomers of vinyl substituted aromatic hydrocarbons having from 8 to 12 carbon atoms.

The vulcanized rubber may be obtained from a number commercial suppliers. and may include a homogeneous or heterogeneous mixture of vulcanized rubber from a variety of manufacturers. Preferably, the vulcanized rubber is obtained from used tires. It is readily appreciated by those having ordinary skill in the art that vulcanized rubber originating from used automobile or truck tires will typically encompass products originating from many manufacturers and comprising a wide assortment of chemical constituents and compositions. Accordingly, a wide variety of different chemicals are expected to be present in the vulcanized rubber.

The vulcanized elastomer (e.g. , the vulcanized rubber) is preferably in the form of small elastomeric particles. The particle size of the vulcanized rubber preferably ranges from 6 to 400 mesh (e.g. , 10, 40, 80, 120, 140, 1 60, 180, 200, 220. 240, 260, 280. 300. 320, 340. 360, 380, 400 mesh, or some range therebetween). The particles size is typical ly between 10 and 200 mesh, and typically between 30 and 40 mesh. Yet, it is anticipated that smaller panicle sizes most preferred, typically greater than 100 mesh, and stil l more preferably greater than 200 mesh. The particle size of the vulcanized rubber may be reduced to the preferred range using any suitable means known in the art. Typically, the vulcanized rubber is mechanically ground, mil led sheared, or otherwise pulverized into a type of rubber known as "crumb rubber." Cryogenic processes for forming crumb rubber may also be employed. See e.g. , Perfido et al. U.S. Patent No. 5,588,600; and Edson, U.S. Patent No. 5,927,627. Further, various commercial suppliers of crumb rubber are known in the art.

Further, as shown in FIG. I prior to applying the alternating radio frequency dielectric field to the vulcanized rubber or other vulcanized elastomer, the vulcanized rubber or other vulcanized elastomer may be combined with virgin or fresh unvulcanized elastomers, such as virgin or fresh unvulcanized rubber. Such virgin or fresh unvulcanized rubber may also be polar or non-polar, such as natural isoprene rubber, styrene-butadiene rubber. butadiene rubber, nitrile-butadiene rubber etc. Typically, the particles of the vulcanized elastomer (e.g. , vulcanized rubber) and the virgin or fresh unvulcanized elastomers (e.g.. unvulcanized rubber) are premixed together. The vulcanized rubber may be present in the composition to be devulcanized at any suitable level - for example, about 10, 20 30, 40, 50, 60, 70, 80, 90, or 100 wt% (or some range therebeween). Preferably, the virgin or fresh rubber comprises at least 10 wt% of the overall composition. This is often determined by the use and application of the rubber product and the desired physical properties.

An alternating radio frequency dielectric field is then applied to the vulcanized rubber (and optional virgin or fresh unvulcanized rubber) composition in a manner that targets select chemical bonds in the vulcanized rubber. In particular, sulfur-carbon and sul fur-sulfur bonds of the vulcanized rubber are targeted by the alternating radio frequency dielectric field. The alternating field causes the molecules to vibrate, which creates internal friction between the rubber molecules. The use of an alternating radio frequency dielectric field to devulcanize crosslinked elastomeric materials results in a relatively even appl ication of the wave energy throughout the material.

For the devulcanization of vulcanized tire rubber (e.g. , crumb rubber), the frequency of the alternating radio frequency dielectric field preferably ranges from about 1 MHz to 100 MHz, more preferably from about 10 to 60 MHz, and most preferably about 25 to 40 MHz. The most preferred frequencies are those allowed center frequencies for industrial, scientific, and medical ("ISM ") applications, namely 27.12 MHz or 40.68 MHz. The voltage preferably ranges from about 1000 to 10,000 V, more preferably about 3000 to 7000 V. and still more preferably about 4000 to 6000 V. The exposure time to the alternating radio frequency dielectric field varies depending upon the voltage applied, the frequency applied, the size of the devulcanization apparatus, and the power factor of the rubber, but typically ranges between a few seconds to up to one minute. For example, application of 4000 V for 30 seconds at 27.1 2 MHz is typically sufficient to devulcanize rubber particles comprised of ground tire rubber. If the voltage is raised to 8000 V but the frequency is maintained at 27.1 2 MHz, the exposure time is decreased, for example to about 7.5 seconds.

The alternating radio frequency dielectric field may be applied to the vulcanized rubber using a number of different devices. An exemplar)' device is illustrated in FIG. 2. In general, the vulcanized rubber is placed between two electrodes such that the rubber effectively becomes the dielectric of a capacitor. An alternating radio frequency dielectric field generated between the electrodes causes polar molecules in the rubber to be attracted and repelled by the rapidly changing polarity of the electric field. The friction resulting from this molecular movement causes a degradation of the crossl ink ing of the rubber.

More speci fically, devulcanizing apparatus 10 includes a top electrode 1 2 and a bottom electrode 14, both of which are connected to an electromagnetic energy source or generator (not shown) operable to generate a dielectric field between the electrodes. For example, the top electrode 1 2 may be the high voltage electrode while the bottom electrode 1 is a ground electrode (or vice versa). The dielectric field may be generated at frequencies ranging from about 1 M Hz to 100 MHz, and is preferably generated from about 25 M Hz to 40 MHz. Most preferably, the dielectric field is generated at either 27.1 2 MHz or 40.68 M Hz (both of which are allowed center frequencies for industrial, scienti fic, and medical ( ISM ) applications). Also included within apparatus 10 are a top mold 16 and a bottom mold 1 8 that together define a molding cavity therebetween. In the illustrated example, a vulcanized rubber composition 20 (with optional fresh or virgin unvulcanized rubber) is placed within the molding cavity. The top mold 16 and the bottom mold 18 are compressed so as lo remove as much air as possible from the molding cavity. An optional vacuum line 25 may be formed in one or both of the top mold 16 or bottom mold 18 in order to further remove air from the molding cavity. In operation, a dielectric field is applied across the rubber composition 20, causing the molecules of the rubber to vibrate and cause devulcanization of the rubber. The temperature of the rubber composition typically increases to about 95 to 1 75 °C, preferably to about 1 20 to 1 30 °C, during the devulcanization process.

The generator may contain a power tube and LC circuit, or may alternatively contain solid-state technology. Preferably, the generator is tuned to resonate at the desired frequency, which occurs when the total capacitance including the load (i. e.. the vulcanized rubber particles) is equal to the total inductance. Once the desired frequency is selected, the capacitance an nductance may be calculated as follows:

where

C = capacitance in Farad

L - inductance in Henry

/= frequency of dielectric field in hertz As shown in FIG. 3, the signal generated by the generator is substantially a sinusoid having a wavelength λ. Preferably, the vulcanized rubber particles between top electrode 12 and bottom electrode 14 arc centered at a position that is ¼ λ from the power tube of the generator. It can be seen that the peak of the sinusoid is located at this ¼ λ position, which provides the most constant voltage (i.e.. the lowest voltage change) on the sinusoid. One skilled in the art will understand that the application of similar voltages across the entire area of the vulcanized rubber particles will result in substantially even heating of the vulcanized rubber particles.

The wavelength of the sinusoid may be expressed as follows:

c

(2) f

where

λ = wavelength of sinusoid in meters

c - speed of light (3 x 10 ⁸ m/scc)

= frequency of dielectric field in hertz '

Using equation (2), the wavelength of a sinusoid for a dielectric field generated at 27.12 MHz is as follows:

3x10 ^s

~ 27.12x10"

= 1 1 .1 meters

= 36.3 feet

Thus. % λ would be located at 9.1 feet from the power tube of the generator.

Similarly, the wavelength of a sinusoid for a dielectric field generated at 40.68 MHz is as follows:

3x10 ⁸

40.68x10"

= 7.5 meters

= 24.6 feet

Thus, ¼ λ would be located at 6.15 feet from the power tube of the generator.

One skilled in the art will understand that the use of a lower frequency {e.g. , 27.12 MHz) will provide more even heating due to the longer wavelength λ. However, the use of a higher frequency (e.g. , 40.68 MHz) will heat the vulcanized rubber particles at a faster rate. Thus, for any given application, the desired frequency may be selected with these considerations in mind. As discussed above, apparatus 10 shown in FIG. 2 may be used to apply similar voltages across the entire area of the vulcanized rubber particles i f placed at or near the ¼ λ position. With this electrode configuration, a single point (designated as point X in FIG. 2) is located at the ¼ wavelength position, which corresponds to the highest voltage on the sinusoid. In order to apply even more consistent voltages across the entire area of the vulcanized rubber particles, top electrode 12 may be replaced with a top electrode in which a plurality of points arc located at the ¼ wavelength position. In order to accomplish this, the top electrode may comprise a plurality of electrically connected plates that are sized and positioned such that each of a plurality of points arc located the same distance (i. e. , ¼ λ) from the power tube of the generator. In a preferred embodiment, the electrically connected plates are arranged in a tiered configuration in which a main plate is located adjacent the top mold and a plurality of smaller plates arc positioned substantially parallel to the main plate at various levels between the main plate and the power tube of the generator. The plates are electrically connected such that a plurality of points on the main plate are each located the same distance (i. e.. ¼ λ) from the power tube of the generator. In effect, by increasing the number of points located at the ¼ λ position, it is possible to substantially flatten-out the peak of the sinusoid. As such, the apparatus is able to apply more consistent voltages across the entire area of the vulcanized rubber particles and, thus, provide more even heating of the vulcanized rubber particles.

An example of such an apparatus is shown as reference numeral I OA in

FIG. 4. It should be understood that the only difference between apparatus 10 of FIG. 2 and apparatus 10A of FIG. 4 is the configuration of the top electrode. In FIG. 2, top electrode 1 2 comprises a single plate. However, in FIG. 4, it can be seen that top electrode 22 includes a main plate 22a electrically connected to plates 22b, 22c, 22d, and 22c. Then, plates 22b and 22c arc electrically connected to plate 22f, and plates 22d and 22e are electrically connected to plate 22g. Further, plates 22f and 22g are electrically connected to plate 22h. which is electrically connected to the power tube of the generator (or other solid-state supply).

As shown in FIG. 4, points A, B, C, D, E, F, G. and H are evenly spaced along the length of main plate 22a, and the power tube of the generator is designated as point O. The size and positioning of the various plates are chosen such that the distances OA, OB, OC, OD, OE, OF, OG, and OH arc the same and, thus, points A, B, C, D, E, F, G, and H arc each located at the ¼ wavelength position. For example, if the selected frequency is 27.1 2 M Hz or 40.68 MHz, each of points A, B, C, D, E, F. G, and H would be located 9.1 feet or 6. 1 5 feet, respectively, from point O. By contrast, as shown in FIG. 2, only point X is located at the ¼ wavelength position. Of course, one skilled in the art will understand that top electrode 22 is merely an example of an electrode that may be used to provide more consistent voltages across the entire area of the vulcanized rubber particles, and that other configurations may also be used in which multiple points are located at the ¼ wavelength position.

FIG. 5 shows the peak of the sinusoid of FIG. 3, with point X (FIG. 2) and points A, B, C, D, E, F, G, and H (FIG. 4) superimposed thereon in order to illustrate the differences between the configurations of top electrode 12 (FIG. 2) and top electrode 22 (FIG. 4). As can be seen, point X and points A, B, C, D, E, F, G, and H are each located at the peak of the sinusoid, which corresponds to the highest voltage. In effect, the configuration of top electrode 22 substantially flattens-out the peak of the sinusoid. As such. top electrode 22 may be used to apply more consistent voltages across the entire area of the vulcanized rubber particles and, thus, provide more even heating as compared to top electrode 12.

While the devulcanizing apparatuses generally shown in FIG. 2 and FIG. 4 arc well adapted to devulcanize rubber and other elastomers in a batch process, it will be appreciated that the alternating radio frequency dielectric field may be applied in a continuous fashion. FIG. 6 illustrates an exemplary devulcanizing apparatus 1 10 in accordance with a second embodiment that is continuous in nature. The devulcanizing apparatus 1 10 includes a top electrode 1 12 and a bottom electrode 1 14, both of which arc connected to an electromagnetic energy source (not shown) operable to generate an alternating electric field between the electrodes. For example, the top electrode 1 1 2 may be the high voltage electrode 1 14 while the bottom electrode is a ground electrode (or vice versa). The top electrode 1 12 may comprise a single plate (e.g., as generally depicted in FIG. 2) or may comprise a plurality of electrically connected plates (e.g. , as generally depicted in FIG. 4). The alternating electric field may be generated at frequencies ranging from about 1 MHz to 100 MHz, and is preferably generated from about 25 MHz to 40 MHz. Also included within apparatus 1 10 is a conveyor 1 18 which is positioned against bottom electrode 1 14 for continuously supplying a composition comprising vulcanized rubber particles 120 (e.g. , crumb runner optionally mixed with fresh or virgin unvulcanized rubber) into the alternating radio frequency dielectric field. The composition comprising the vulcanized rubber particles 120 is preferably metered through hopper 130 to one or more set of rollers 132, 134 to form a generally continuous sheet of vulcanized rubber particles (and optional fresh or virgin unvulcanized rubber). The rollers generally compress the vulcanized rubber particles, which assists with removal of air from the rubber. In the il lustrated example, vulcanized rubber (along with the optional virgin or fresh unvulcanized rubber) is metered through the rollers 132, 1 34 onto the conveyor 1 1 8 so as to remove as much air as possible from the rubber composition 1 20. In operation, an alternating dielectric field is applied across the rubber composition 1 20, causing the molecules of the rubber to vibrate and cause devulcanization of the rubber. One or more rollers, presses, or other compacting devices 136 may be used to compress the sheet material during or after the devulcanization process, preferably while the devulcanized rubber is hot. The temperature of the rubber composition typically increases to about 95 to 1 75 °C, preferably about 1 20 to 1 30 °C, during the devulcanization process.

FIG. 7 il lustrates a devulcanizing apparatus 210 in accordance with a third embodiment. The devulcanizing apparatus 210 includes a plurality of top transverse electrode rods 2 12 and a plurality of bottom transverse electrode rods 21 . For example, the top transverse electrode rods may be the high voltage electrodes while the bottom transverse electrode rods are the ground electrodes (or vice versa). The rods 21 2, 214 are connected to an electromagnetic energy source (not shown) operable to generate an alternating electric field between the electrode rods. The alternating electric field may be generated at frequencies ranging from about 1 MHz to 1 00 MHz, and is preferably generated from about 25 MHz to 40 MHz. Also included within apparatus 210 is a conveyor 21 8 which is positioned over the bottom electrode rods 214 for continuously supplying a composition comprising vulcanized rubber particles 220 (e.g. , crumb rubber optionally mixed with virgin or fresh unvulcanized rubber) into the alternating radio frequency dielectric field. The vulcanized rubber particles 220 are preferably metered through hopper 230 to one or more set of rol lers 232, 234 to form a generally continuous sheet of vulcanized rubber particles. The rollers generally compress the composition comprising vulcanized rubber particles 1 20, which assists with removal of air from the rubber. In the illustrated example, vulcanized rubber 220 (along with the optional virgin or fresh unvulcanized rubber) is metered onto the conveyor 210 and through the rol lers 232, 234 so as to remove as much air as possible from the rubber composition. In the operation, an alternating dielectric field is applied across rubber 220, causing the molecules of the rubber to vibrate and cause devulcani zation of the rubber. One or more rol lers, presses, or other compacting devices 236 may be used to compress the sheet material during or after the devulcanization process, preferably while the devulcanized rubber is hot. The temperature of the rubber composition typically increases to about 95 to 175 °C, preferably about 120 to 130 °C, during the devulcanization process.

The present invention is also directed to a process for revulcanizing the devulcanized elastomers formed using the alternating radio frequency dielectric field as discussed herein. That is, as generally shown in FIG. 1 , the devulcanized elastomers formed by application of the alternating radio frequency dielectric field may be revulcanized in order to provide new useful articles. The devulcanized elastomers formed using the alternating radio frequency dielectric field may also be combined with other polymer stocks (such as virgin or fresh unvulcanized rubber) and then revulcanized or otherwise crosslinked.

In an exemplary embodiment, the rubber devulcanized in accordance with the present invention is revulcanized - cither alone or by combining the devulcanized rubber with virgin or fresh unvulcanized rubber and then subjecting it to a vulcanization process. The devulcanized rubber formed using the alternating radio frequency dielectric may present in the composition to be revulcanized at any suitable level - for example, about 10, 20 30, 40, 50, 60, 70, 80, 90, or 100 wt%. Preferably, the devulcanized rubber comprises at least 10 wt% of the end product. For certain articles such as belts, hoses, or shoe treads, it may be possible to use 100% devulcanized rubber during the rcvulcanization process.

The devulcanized rubber of the present invention may be used to form a variety of tire tread and tire tread cap rubber compositions such as those taught in Bauer et al., U.S. Patent No. 5,378,754, and Burlett et al., U.S. Patent No. 5,023,301 , which are incorporated herein by reference. For instance, the devulcanized rubber may be blended with a rubber selected from the group consisting of cis-l ,4-polyisoprene (natural or synthetic), cis- 1 ,4-polybutadienc, 3,4-polyisoprenc. styrene butadiene copolymers, styrene/isoprene/butadiene terpolymers. butadiene/acrylonitrile copolymers. isoprene/acrylonitrile copolymers, nitrile butadicne copolymers and mixtures thereof.

The devulcanized rubber of the present invention may also be combined with a suitable filler. Examples of fillers include, but arc not limited to, silica, alumina, diatomaceous earths, titanium dioxide, iron oxide, zinc oxide, magnesium oxide, metal ferrite, and other such oxides: aluminum hydroxide, magnesium hydroxide, and other such hydroxides; calcium carbonate (light and heavy), magnesium carbonate, dolomite, dawsonitc, and other such carbonates; calcium sulfate, barium sulfate, ammonium sulfate, calcium sulfite, and other such sulfates and sulfites; talc, mica, clay, glass fiber, calcium silicate, montmorillonite, bentonite, and other such silicates; zinc borate, barium inelaborate, aluminum borate, calcium borate, sodium borate, and other such borates; carbon black, graphite, carbon fiber, and other such forms of carbon; as well as powdered iron, powdered copper, powdered aluminum, zinc flowers, molybdenum sulfate, boron fiber, potassium titanate, and lead titanate zirconate.

Synthetic resins can be utilized as the organic fillers. Examples include powders of alkyd resins, epoxy resins, silicone resins, phenolic resins, polyester, acrylic resins, acetal resins, polyethylene, polyether, polycarbonate, polyamide, polysulfone, polystyrene, polyvinyl chloride, fluoro resins, polypropylene, ethylene-vinyl acetate copolymers, and various other such thermosetting resins or powder of thermoplastic resins, or po\vdcrs of copolymers of these resins. Further, other examples of organic fillers which can be utilized include aromatic or aliphatic polyamide fibers, polypropylene fibers, polyester fibers, and aramid fibers.

Antioxidants, UV light stabilizers, and processing oils can be included as well. Antioxidants include physical protectorants and chemicals which minimize oxidation. The chemicals include amines, phenolics, and phosphites. Processing oils are usually chosen based on compatibility with the rubber and desirable color and/or aging properties. They may be organic ester plasticizers, mineral oils, vegetable oils, paraffinic oils, naphthenic oils, or other aromatic oi ls. The rubber composition may also include lubricants, antistatic agents, pigments, dyes, flame retardants. or processing aids, which are all well known to those ki l led in the art.

The methods used to re-vulcanize the clastomeric material that was previously devulcanized using the alternating radio frequency dielectric field include any of those known in the art. In general, the vulcanization system is one suitable for reacting with and crosslinking the elastomcric material. Depending on the elastomer, suitable crosslinking or curing agents include sulfur, sulfur donors, peroxides, metallic oxides, diamines, bismaleimides, and the like. Powdered sulfur, su l fur flowers, sul fur chloride, deoxygenatcd sulfur, sediment sulfur, colloidal sulfur, surface-treated sulfur, and the like can be used as the sulfur. Peroxides which may be utilized include, for example, di-t-butyl peroxide, 1- butylcumyl peroxide, dicumyl peroxide, and other such dialkyl peroxides, acetyl peroxide, lauroyl peroxide, benzoyl peroxide, and other such diacyl peroxides, methyl ethyl ketone peroxide, cyclohexanone peroxide, 3,3,5-trimethyl cyclohexanone peroxide, methyl cyclohcxanone peroxide, and other such ketone peroxides, 1 , 1 -bis (t-butyl peroxy) cyclohexane, and other such peroxyketals, t-butyl hydroperoxide, cumene hydroperoxide. 1 , 1 ,3,3-tetramelhyl butyl hydroperoxide, p-menthane hydroperoxide, diisopropylbenzene hydroperoxide, 2,5-dimethylhexane-2,5-dihydroperoxide, and other such hydroperoxides, l- butyl peroxyacetate, t-butylperoxy-2-cthyl hexanoate, t-butyl peroxybenzoate, t-butyl peroxyisopropyl carbonate, and other such peroxy esters. Examples of maleimide crosslinking agents are m-phenylene bismaleimide (4,4'-m-phenylene bismaleimide), 4,4'- vinylenediphenyl bismaleimide, p-phenylene bismaleimide, 4,4'-sul fonyldiphenyl bismaleimide, 2,2'-dithiodiphenyl bismaleimide, 4,4'-ethylene-bis-oxophenyl bismaleimide, 3,3'-dichloro-4,4'-biphenyl bismaleimide, hexamethylene bismaleimide, and 3,6-durine bismaleimide. Zinc oxide may be used alone or in combination with other crosslinking agents for halogenated rubbers such as bromobutyl rubbers. Resin crosslinking agents can be used. The resins include methylol phenolic resins, brominated phenol ic ^' resins, urethane resins etc. The most preferred crossl inking agent is sulfur. It is preferably used in an amount of about 0.1 to about 3.0 parts by weight per 100 parts by weight of the rubber polymer. The preferred amount of sul fur is about 1.0 to 2.0 wt%.

Various vulcanization accelerators, promoters, and/or initiators can be added to the vulcanization mixture. Typical vulcanization accelerators include, but are not necessarily limited to: guanidine type vulcanization accelerators, aldehyde-ammonia type vulcanization accelerators, sulphenamide Jype vulcanization accelerators, thiuram type vulcanization accelerators, xanthate type vulcanization accelerators, aldehyde-aniine type vulcanization accelerators, thiazole type vulcanization accelerators, thiourea type vulcanization accelerators, dithiocarbamate type vulcanization accelerators, and mixed types of these. Examples of vulcanization accelerators include, for example, tetramethylthiuram disulfide ("TMTD"), tetramethylthiuram monosulfide ("T TM"), N-oxydiethylene-2- benzothiazolyl sulfenamide ("OBS"), N-cyclohexyl-2-benzothiazyl sul fenamide ("CBS"). N- t-butyl-2-benzothiazyl sulfenamide ("TBBS"), benzothiazyl-2-sulphene morphol ide ("MBS"), N-dicyclohexyl-2-benzothiazyl sulfenamide ( "DCBS"), tetramethylthiuram disul fide ("TMTD"); diphenylguanidine ("DPG"), mercaptobenzothiazole (MBT), mercaptobenzothiazole disulfide ("MBTS"). the zinc salt of mercaptobenzothiazole ("ZMBT"), tetramethylthiuram hexasulfide, N,N-diphenylurea, mo holinethiobenzothiazo)e, zinc di-n-butyl dithiocarbamate, zinc dimethyl dithiocarbamate, and zinc flowers. Examples of guadinide type vulcanization accelerators include diphenyl guanidine, triphenyl guanidine. di-ortho-tolyl guanidine, ortho-tolyl biguanide, and diphenyl guanidine phthalate. Examples of aldehyde-ammonia vulcanization accelerators include hexamethylene diamine and acetaldehyde-ammonia. Examples of thiuram vulcanization accelerators include tetramethylthiuram monosulfide, tetramethylthiuram disulfide, tetraethylthiuram disulfide, tetrabutylthiuram disulfide, and dipentamethylenethiuram tetrasulfide. Examples of aldehyde-amine vulcanization accelerators include the reaction product of butyraldehyde and ani line and aldehyde-ammonia compounds such as hcxamethylene diamine and acetaldehyde-ammonia. Examples of xanthate type vulcanization accelerators include, but are not necessarily limited to: sodium isopropylxanthate, zinc isopropylxanthate, zinc ethylxanthate, zinc butylxanthate, and dibutyl xanthate disulfide. Examples of thiazole type vulcanization accelerators include N cyclohexyl-2-benzothiazole sul fenamiden, N- oxydiethylene-2-benzothiazolesulfenamide. N,N-diisopropyl-2-benzothiazole sulfanamide, 2- mercaptobenzothiazole, 2-(2,4-dinitrophenyl)mercaptobenzothiazole, 2-(2,6-diethyl-4- moφholinoth!o)benzothiazole, and benzothiazyldisulfide. Examples of thiourea vulcanization accelerators include thiocarbanilide, diethylthiourea. dibutylthiourea, trimethylthiourea, and di-ortho-tolyl thioure. Examples of dithiocarbamate type vulcanization accelerators include, but are necessarily limited to: sodium dimethyldithiocarbamate, sodium diethyldithiocarbamate, sodium di-n-butyldithiocarbamate. zinc ethylphenyldithiocarbamate, zinc dimethyldithiocarbamate, zinc diethyldithiocarbamate, zinc di-n-butyldithiocarbamate, zinc dibenzylthiocarbamate, zinc N-penta- methylenedithiocarbamale, zinc dimcthylpentamethylenedithio-carbamate, zinc ethylphenyldithiocarbamate, selenium dimethyldithiocarbamate. selenium diethyldithiocarbamate, tellurium diethyldithiocarbamate, cadmium diethyldithiocarbamate. dimethylammonium dimethyldithiocarbamate, dibutylammonium dibutyldithiocarbamate, diethylamine diethyldithiocarbamate, N.N'-dimethylcyclohexane salt of dibutyldithiocarbamic acid, pipccolic methylpentamethylenedithiocarbamate, and the li ke.

Depending on the particular vulcanization accelerator employed, preferred amounts of accelerator typical ly range from about 0. 1 to about 3.0 parts by weight per 100 parts by weight of the rubber polymer. For example, an accelerator system comprising about 0.5 to 2 wt% BTS and 0. 1 to 0.3 wt% TMTD may be employed for devulcanized crumb rubbers from most tires during the revulcanization process V ulcanization times, which may differ depending on the crosslinking agent, the vulcanization accelerator and the vulcanization temperature.

A coupling agent may also be used in the present invention. There are no specific limitations on the coupling agent, and selections suited to objectives can be made. However, a typical silane coupling agent like Si69. Examples of other silane coupl ing agents may include bis(3-triethoxysilylpropyl)tetrasul f ide, bis(2- l triethoxysilylelhyl )tetrasul l]de. bis(3-trimethoxysilylpropyI)tetrasui nde, bis(2-trimethoxysilylcthyl)tetrasul fide. 3- mercaptopropyltrimethoxysilane, 3-mercaptopropyltriethoxysilane, 2- mercaptoethyltrimethoxysilane, 3-nitropropyltrimethoxysilane, 3-nitropropyltriethoxysilane, 3-chloropropyltrimethoxysilane, 3-chloropropyltriethoxysilane, 2- chloroethyltrimethoxysilane, 2-chloroethyltriethoxysilane, 3-trimethoxysilylpropyl-N,N'- dimethylthiocarbamoyltetrasul fide, 3-triethoxysilylpropyl-N.N'- dimethylthiocarbamoyltetrasulfide. 2-triethoxysilylethyl-N,N- dimethylthiocarbamoyltetrasulfide, 3-trimethoxysilylpropylbenzothiazoletetrasul fide, 3- triethoxysilylpropylbenzothiazoletetrasulfide, 3- triethoxysilylpropylmethacrylatemonosulfide, and 3- trimthoxysilylpropylmethacrylayemonosulfide.

In a preferred aspect, the elastomers that have been devulcanized using alternating radio frequency dielectric field are revulcanized using one of two preferred methods. The first involves heating the devulcanized elastomers (preferably with virgin or fresh unvulcanized rubber) to suitable temperature for a suitable time. Typically, heating in an oven for at 150 °C to 1 80 ^* C for five to 25 minutes wil l result in sufficient revulcanization. Second, the elastomers may be heated in a radio frequency mold, such as one described in Marc, U.S. Published Patent Application No. 2009/236030, which is incorporated by reference. The frequency of the alternating dielectric radio frequency field preferably ranges from about 1 MHz to 100 MHz, more preferably from about 10 MHz to 60 MHz, and most preferably about 25 MHz to 40 MHz. The voltage ranges from about 1000 to 10,000 V, more preferably about 3000 to 7000 V, and still more preferably about 4000 to 6000 V. The exposure time to the alternating radio frequency dielectric field varies depending upon the voltage applied, but typically ranges between several seconds to up to two minutes. Thus, the exposure time is generally longer than that utilized to devulcanize the elastomer. For example, application of 8000 V for 10 to 50 seconds at 27.12 MHz is typically sufficient to vulcanize a rubber composition about 0. 1 to 1 .0 inch thick having a sul fur crosslinking agent added thereto.

It will be appreciated that whi le Marc, U.S. Published Patent Appl ication No. 2009/236030 describes a process for vulcanizing rubber using an alternating radio frequency dielectric field, the present invention described herein is one in which vulcanized rubber is devulcanized using an alternating radio frequency dielectric field. Vulcanization typically requires much higher temperatures (on the order of 1 50 to 220 °C, and typically about 160 to 190 °C) and the addition of a crosslinking agent - although theoretically some crosslinking may occur by virtue of residual sulfur in the devulcanized rubber.

The examples below are intended to illustrate the present invention. The descriptions in no way limit the scope of the present invention. In the examples, the properties of the combination of vulcanized rubber samples are evaluated as follows:

Coefficient of friction: Measured using an aluminum sheet.

Abrasion Weight Loss: Loss of weight after 4000 revolutions on a diamond wheel abrader.

Tensile Strength: Measurements were carried out in accordance with ASTM Standard D412, test method A.

Elongation at Break: Measured as a percentage value according to ASTM standard D412, test method A.

Shore Hardness: Measurements carried out in accordance with ASTM

Standard D2240.

Modulus 300%: Measurements were carried out in accordance with ASTM Standard D 12, test method A.

Example 1 : Truck and Car Tire Rubber

In this example, the physical parameters of vulcanized tire rubber derived from unground tires are shown column 1 of Table 1 . For comparison, vulcanized ground tire rubber ("VGTR") obtained from a mixture of truck and car tires from Quest Recycling Services (Concordia, S) was devulcanized by applying an alternating radio frequency dielectric field having a voltage of about 4000 to 6000 V at a frequency of 27.1 2 M Hz for about 30 to 50 seconds. The VGTR likely comprised a mixture of nitrile-butadiene rubber and styrene-butadiene rubber in unknown ratios having a 30 mesh particle size. The VGTR was placed in a mold that measures 8 x 12 inches and was about ¼-inch thick and generally configured as shown in FIG. 2.

Following devulcanization, the devulcanized ground tire rubber ("DGTR") was combined with varying amounts of virgin or fresh unvulcanized rubber ("FR") and then vulcanized. The FR comprised a mixture of isoprene, styrene butadiene, polybutadiene, filler, zinc oxide, stearic acid, oil, sulfur, and accelerator. About 2.5 wt% (based on the weight of the rubber) of sulfur, 1 .75% MBTS. and 0.3% TMTD was added to the varying DGTR FR compositions and then the composition was heated in an oven. During vulcanization, the temperature of ^" the rubber composition reached temperature of about 160 to 190 °C. The properties the revulcanizcd compositions from the VGTR that has been dcvulcanized to form DGTR using the alternating radio frequency dielectric Held are shown in columns 2-7 of Table 1 .

Example 2: Shoe Rubber

In this example, the physical parameters of vulcanized shoe sole rubber derived from composition comprising virgin or fresh shoe sole rubber ("FSSR") and scrap dcvulcanized ground shoe sole rubber ("DGSSR") are shown in Table 2. Vulcanized ground shoe sole rubber ("VGSS R") was ground into small particles (40 mesh) and devulcanizcd by applying an alternating radio frequency dielectric field having a voltage of about 4000 to 6000 V at a frequency of 27.12 MHz for about 30 to 50 seconds. The VGSSR was placed in a mold that measures 8 x 12 inches and was about 1/8-inch thick and generally configured as shown in FIG. 2.

Following devulcanization, the DGSSR was combined with varying amounts of FSSR and then vulcanized. More specifically, about 1 .1 wt% (based on the weight of the rubber) of sulfur, 0.8% MBTS, and 0.12% TMTD was added to the varying DGSSR/FSSR compositions and then the composition was heated in an oven. During vulcanization, the temperature of the rubber composition reached temperature of about 160 °C over a period of six minutes. The properties the revulcanizcd compositions from the VGSSR that has been devulcanizcd to form DGSSR using the alternating radio frequency dielectric field are shown in Table 2. Table 2: Ph sical Pro erties of VGSSR and Revulcaniy.ed DGSSR/FSS

Example 3: Passenger Car Tire Rubber

In this example, the physical parameters of vulcanized passenger car tire rubber derived from composition comprising virgin or fresh rubber (" FR") and devulcanized ground passenger car tire rubber ("DGCTR") are shown in Table 3. The vulcanized ground passenger car tire rubber ("VGCTR") from Lehigh Technologies (Tucker, GA) had a particle size of 40 mesh, and was devulcanized by applying an alternating radio frequency dielectric field having a voltage of about 4000 to 6000 V at a frequency of 27.12 M Hz for about 30 to 50 seconds. The VGCTR was placed in a mold that measures 8 x 12 inches and was about ¼-inch thick and generally configured as shown in FIG. 2.

Following devulcanization, the devulcanized ground tire rubber ("DGCTR") was combined with varying amounts of virgin or fresh unvulcanized rubber ("FR") and then vulcanized. The FR comprised a mixture of isoprene, styrene butadiene, polybutadiene, filler, zinc oxide, stearic acid, oil, sulfur, and accelerator. More specifically, about 2.5 wt% (based on the weight of the rubber) of sul fur, 1 .75% MBTS. and 0.3% TMTD was added to the varying DGCTR/FR compositions and then the composition was heated in an oven. During vulcanization, the temperature of the rubber composition reached temperature of about 1 60 to 1 90 °C. The properties the revulcanized compositions from the VGCTR that has been devulcanized to form DGCTR using the alternating radio frequency dielectric field are shown in Table 3. Table 3: Physical Properties of Revulcanized DGCTR/FR

70% DGCTR 70% DGCTR

(Mesh 40) (Mesh 105) 30%

Properties 100% F 30% FR FR

Coefficient of Friction .75 .734 1 .1 6

Abrasion Weight Loss (g) .02 NA .07

Tensile (kg/cm ² ) 1 13 129.5 125

Elongation at Break (%) 450% 350% 440%

Hardness Shore A 69 73 72

From the foregoing it will be seen that this invention is one wel l adapted to attain all ends and objectives herein-above set forth, together with the other advantages which are obvious and which are inherent to the invention. Since many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as il lustrative, and not in a limiting sense. Whi le specific embodiments have been shown and discussed, various modifications may of course be made, and the invention is not limited to the specific forms or arrangement of parts and steps described herein, except insofar as such limitations are included in the following claims. Further, it will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.