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  • C08J3/20—Compounding polymers with additives, e.g. colouring
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  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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  • B29B9/00—Making granules
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  • C01B32/00—Carbon; Compounds thereof
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  • C01B32/158—Carbon nanotubes
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  • C08J3/00—Processes of treating or compounding macromolecular substances
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• • H—ELECTRICITY
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  • H01M10/00—Secondary cells; Manufacture thereof
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  • H01M4/00—Electrodes
  • H01M4/02—Electrodes composed of, or comprising, active material
  • H01M4/36—Selection of substances as active materials, active masses, active liquids
  • H01M4/38—Selection of substances as active materials, active masses, active liquids of elements or alloys
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  • H01M4/00—Electrodes
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  • H01M4/36—Selection of substances as active materials, active masses, active liquids
  • H01M4/58—Selection of substances as active materials, active masses, active liquids of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy; of polyanionic structures, e.g. phosphates, silicates or borates
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  • H01M4/62—Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
  • H01M4/624—Electric conductive fillers
  • H01M4/625—Carbon or graphite
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
  • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
  • B29K2105/16—Fillers
  • B29K2105/162—Nanoparticles
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  • C08L2203/00—Applications
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• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
  • Y02E60/10—Energy storage using batteries

Definitions

• the present invention relates to a process for preparing a masterbatch comprising sulfur, more generally comprising a sulfur-containing material, and carbon nanofillers, as well as the masterbatch thus obtained and its various uses.
• the invention also relates to a solid composition comprising carbon nanofillers dispersed in a sulfur material.
• Sulfur is very widely and commonly used in many fields of industry, including the chemical industry as a synthetic reagent for the preparation of various chemical compounds, such as for example sulfuric acid, sulfur dioxide, oleums, carbon disulfide, sulphites or sulphates for the paper industry, phosphorus pentasulfides as lubricating agent.
• Sulfur is also used as elemental sulfur of formula S 8 , for vulcanizing tires, as an agricultural fungicide, or as sulfur polymers for cements and concretes, or as a heat transfer or storage fluid, especially for power plants (thermal or nuclear) or for solar panels, as well as active ingredient for Li / S battery electrode.
• elemental sulfur An important raw material for elemental sulfur is hydrogen sulphide, recovered from the exploitation of natural gas deposits or by desulphurization of crude oils. Since natural gas reserves tend to run out, elemental sulfur can be extracted directly by drilling the earth's crust, since sulfur is a relatively non-metallic element (only 0.06% of the earth's crust, but easily extractable). and nontoxic.
• carbon nanofillers such as carbon nanotubes (CNTs)
• CNTs carbon nanotubes
• a conductive composite material obtained from a chemical treatment of sulfur and carbon, introduced into a sealed reactor without external regulation of the pressure inside the reactor, is described at a temperature between 115 ° C and 400 ° C, for a time sufficient to melt the sulfur and reach an equilibrium.
• This material is in the form of carbon-coated sulfur particles with a low specific surface area.
• the method of introducing carbon into sulfur, described herein, is applicable only to carbon nanofillers without form factor or aggregation.
• the invention can be applied more generally to "sulfur donor" sulfur materials.
• the subject of the invention is a process for the preparation of a masterbatch comprising from 0.01% to 50% by weight of carbonaceous nanofillers, comprising:
• carbon nanobond is meant a filler comprising at least one member of the group consisting of carbon nanotubes, carbon nanofibres, graphene, and carbon black, or a mixture thereof in all proportions.
• the carbon nanofillers are carbon nanotubes, alone or mixed with graphene.
• sulfurized material is meant elemental sulfur, or “sulfur donor” compounds such as sulfur-containing organic compounds or polymers and sulfur-containing inorganic compounds such as anionic alkali metal polysulfides.
• elemental sulfur is used as a sulfur-containing material, alone or as a mixture with at least one other sulfur-containing material.
• liquid sulfur has viscosity varies greatly and non-linearly as a function of temperature.
• one of the technical constraints of the compounding device is a relatively narrow melt process window. The control of the rheology of the charged liquid sulfur must then be carried out with perfect control of the process operating conditions with the possible help of additives which reduce the viscosif ⁇ cation beyond 140 ° C.
• the method according to the invention makes it possible to create a homogeneous association of carbon nanofillers particles with sulfur, thus conferring on it mechanical and / or conductive properties used in many applications.
• the subject of the invention is also the masterbatch capable of being obtained according to the process described above.
• Another aspect of the invention relates to the use of the masterbatch as a vulcanizing agent for elastomers for the manufacture of body seals or seals, tires, noise plates, static dissipators, diapers internal conductor for high and medium voltage cables, or anti-vibratory systems such as automobile shock absorbers, or in the manufacture of structural elements of bullet-proof vests, or as an active ingredient for the manufacture of electrodes for Li / S batteries or supercapacitors, without this list being exhaustive.
• the invention also relates to a solid composition
• a solid composition comprising from 0.01 to 50% by weight, preferably from 1 to 30% by weight, of carbon nanofillers dispersed in a sulfur-containing material, as well as to its various uses.
• FIG. 1 illustrates at the SEM the morphology of the S / NTC masterbatch obtained in Example 1 according to the invention.
• Figure 2 shows the particle size distribution of the powder obtained in Example 1 according to the invention.
• FIG. 3 illustrates by SEM the homogeneous morphology in the mass of a particle of the powder obtained in Example 1 according to the invention.
• the method according to the invention is implemented in a compounding device.
• compounding device is meant, according to the invention, an apparatus conventionally used in the plastics industry for the melt blending of thermoplastic polymers and additives in order to produce composites.
• This type of apparatus has never been used to achieve an intimate mixture of sulfur and / or sulfur material and carbon nanofillers.
• the sulfur-containing material and the carbon nanofillers are mixed using a high-shear device, for example a co-rotating twin-screw extruder or a co-kneader.
• the melt generally comes out of the apparatus in solid physical form agglomerated, for example in the form of granules, or in the form of rods which, after cooling, are cut into granules.
• the shaft is rotated and provided with oscillation movement in the axial direction by a motor.
• co-kneaders may be equipped with a granule manufacturing system, adapted for example to their outlet orifice, which may consist of an extrusion screw or a pump.
• the co-kneaders that can be used according to the invention preferably have an L / D screw ratio ranging from 7 to 22, for example from 10 to 20, while the co-rotating extruders advantageously have an L / D ratio ranging from 15 to 56, for example from 20 to 50.
• the compounding step is carried out at a temperature greater than the melting temperature of the sulfur-containing material.
• the compounding temperature can range from 120 ° C to 150 ° C.
• the compounding temperature is a function of the specifically used material whose melting temperature is generally mentioned by the material supplier.
• the residence time will also be adapted to the nature of the sulfur material.
• elemental sulfur Different sources of elemental sulfur are commercially available.
• the particle size of the elemental sulfur powder can vary widely.
• the elemental sulfur can be used as it is, or the sulfur can be previously purified by different techniques such as refining, sublimation, or precipitation.
• Elemental sulfur or sulfurized material may also be subjected to a prior grinding and / or sieving step in order to reduce the size of the particles and to narrow their distribution.
• organic polysulphides organic polythiolates including, for example, functional groups such as dithioacetal, dithioketal or trithioorthocarbonate, aromatic polysulfides, polyether-polysulphides, sodium salts and the like.
• polysulfides thiosulfonates [-S (O) 2 -S-], thiosulfinates [-S (O) -S-], thiocarboxylates [-C (O) -S-], dithiocarboxylates [-R ( S) -S-], thiophosphates, thiophosphonates, thiocarbonates, organometallic polysulfides, or mixtures thereof.
• organo-sulfur compounds are described in particular in document WO 2013/155038.
• a sulfur-containing inorganic compound for example chosen from anionic alkali metal polysulfides, such as lithium, may be used as sulfurized material.
• the sulfur material is an aromatic polysulfide.
• aromatic polysulfides have the following general formula (I):
• R 1 to R 9 represent, identically or differently, a hydrogen atom, a radical -OH or -O " M + , or a saturated or unsaturated carbon chain containing from 1 to 20 carbon atoms, or a group -OR 10, with R y may be an alkyl radical, arylalkyl, acyl, carboalkoxy, alkyl ether, silyl, silyl alkyl having 1 to 20 carbon atoms.
• M represents an alkaline or alkaline-earth metal
• n and n ' are two integers, identical or different, each being greater than or equal to 1 and less than or equal to 8,
• p is an integer from 0 to 50
• A is a nitrogen atom, a single bond, or a saturated or unsaturated carbon chain of 1 to 20 carbon atoms.
• R 1, R 4 and R 7 are 0 " M + radicals
• R2, R5 and Rs are hydrogen atoms
• R3, R9 and R9 are saturated or unsaturated carbon chains having 1 to 20 carbon atoms, preferably 3 to 5 carbon atoms, the average value of n and n 'is about 2,
• the average value of p is between 1 and 10, preferably between 3 and 8. (These average values are calculated by those skilled in the art from proton NMR data and by weight assay of sulfur).
• - A is a single bond linking the sulfur atoms to the aromatic rings.
• poly (alkyl phenol) polysulfides of formula (I) are known and can be prepared for example in two steps:
• R is tert-butyl or tert-pentyl.
• a mixture of compounds of formula (I) in which 2 R radicals present on each aromatic unit are used are carbon chains comprising at least one tertiary carbon by which R is linked to the aromatic ring.
• the amount of carbon nanofillers represents from 0.01% to 50% by weight, preferably from 1% to 30% by weight, more preferably from 5% to 25% by weight relative to the total weight of the masterbatch.
• the carbon nanofillers are carbon nanotubes, carbon nanofibres, graphene, or carbon black, or a mixture of these in all proportions.
• the carbon nanofillers are nanotubes of carbon, alone or mixed with at least one other conductive carbonaceous filler, preferably with graphene.
• the carbon nanotubes used in the composition of the masterbatch can be single-walled, double-walled or multi-walled.
• the double-walled nanotubes can in particular be prepared as described by FLAHAUT et al in Chem. Com. (2003), 1442.
• the multi-walled nanotubes may themselves be prepared as described in WO 03/02456.
• the carbon nanotubes used according to the invention usually have a mean diameter ranging from 0.1 to 200 nm, preferably from 0.1 to 100 nm, more preferably from 0.4 to 50 nm and better still from 1 to 100 nm. at 30 nm, or even 10 to 15 nm, and advantageously a length of more than 0.1 ⁇ and preferably 0.1 to 20 ⁇ , preferably 0.1 to 10 ⁇ , for example about 6 ⁇ . Their length / diameter ratio is advantageously greater than 10 and most often greater than 100.
• These nanotubes therefore comprise in particular nanotubes known as "VGCF" (carbon fibers obtained by chemical vapor deposition or Vapor Grown Carbon Fibers).
• Their specific surface area is for example between 100 and 300 m 7 G, preferably between 200 and 300 m 7 G, and their apparent density may in particular be between 0.01 and 0.5 g / cm 3 and more preferably between 0.07 and 0, 2 g / cm 3 .
• the multi-walled carbon nanotubes may for example comprise from 5 to 15 sheets and more preferably from 7 to 10 sheets.
• These nanotubes may or may not be processed.
• An example of crude carbon nanotubes is in particular the trade name Graphistrength ® Cl 00 from Arkema.
• nanotubes can be purified and / or treated (for example oxidized) and / or milled and / or functionalized.
• the grinding of the nanotubes may in particular be carried out cold or hot and be carried out according to known techniques used in devices such as ball mills, hammers, grinders, knives, gas jet or any other system. Grinding capable of reducing the size of the entangled network of nanotubes. It is preferred that this grinding step is performed according to a gas jet grinding technique and in particular in an air jet mill.
• the purification of the crude or milled nanotubes can be carried out by washing with a sulfuric acid solution, so as to rid them of any residual mineral and metal impurities, such as for example iron from their preparation process. .
• the weight ratio of the nanotubes to the sulfuric acid may especially be between 1: 2 and 1: 3.
• the purification operation may also be carried out at a temperature ranging from 90 to 120 ° C, for example for a period of 5 to 10 hours. This operation may advantageously be followed by rinsing steps with water and drying the purified nanotubes.
• the nanotubes may alternatively be purified by high temperature heat treatment, typically greater than 1000 ° C.
• the oxidation of the nanotubes is advantageously carried out by putting them in contact with a solution of sodium hypochlorite containing from 0.5 to 15% by weight of NaOCl and preferably from 1 to 10% by weight of NaOCl, for example in a weight ratio of nanotubes to sodium hypochlorite ranging from 1: 0.1 to 1: 1.
• the oxidation is advantageously carried out at a temperature below 60 ° C. and preferably at room temperature, for a period ranging from a few minutes to 24 hours. This oxidation operation may advantageously be followed by filtration and / or centrifugation, washing and drying steps of the oxidized nanotubes.
• the functionalization of the nanotubes can be carried out by grafting reactive units such as vinyl monomers on the surface of the nanotubes.
• the material constituting the nanotubes is used as a radical polymerization initiator after having been subjected to a heat treatment at more than 900 ° C., in an anhydrous and oxygen-free medium, which is intended to eliminate the oxygenated groups from its surface. It is thus possible to polymerize methyl methacrylate or hydroxyethyl methacrylate on the surface of carbon nanotubes.
• raw nanotubes of crushed carbon that is to say nanotubes which are neither oxidized nor purified nor functionalized and have undergone no other chemical and / or thermal treatment.
• Carbon nanotubes obtained from renewable raw material, in particular of vegetable origin, as described in application FR 2 914 634.
• Carbon nanofibers like carbon nanotubes, are nano-filaments produced by chemical vapor deposition (CVD) from a carbon source which is decomposed on a catalyst comprising a transition metal (Fe, Ni, Co , Cu), in the presence of hydrogen, at temperatures of 500 to 1200 ° C.
• CVD chemical vapor deposition
• a carbon source which is decomposed on a catalyst comprising a transition metal (Fe, Ni, Co , Cu)
• these two carbonaceous charges are differentiated by their structure (I. MARTIN-GULLON et al., Carbon 44 (2006) 1572-1580).
• the carbon nanotubes consist of one or more sheets of graphene wound concentrically around the axis of the fiber to form a cylinder having a diameter of 10 to 100 nm.
• carbon nanofibers are composed of more or less organized graphitic zones (or turbostratic stacks) whose planes are inclined at variable angles with respect to the axis of the fiber. These stacks can take the form of platelets, fish bones or stacked cups to form structures generally ranging in diameter from 100 nm to 500 nm or more.
• the carbon nanofibers having a diameter of 100 to 200 nm e.g., about 150 nm (VGCF ® from SHOWA DENKO), and advantageously a length of 100 to 200 ⁇ .
• graphene is meant a sheet of graphite plane, isolated and individualized, but also, by extension, an assembly comprising between one and a few tens of sheets and having a flat structure or more or less wavy.
• This definition therefore encompasses FLG (Few Layer Graphene or low stacked graphene), NGP (Nanosized Graphene Plates or nanoscale graphene plates), CNS (Carbon NanoSheets or nano-graphene sheets), GNR (Graphene NanoRibbons or nano-ribbons of graphene).
• the graphene used according to the invention is not subjected to an additional step of chemical oxidation or functionalization.
• the graphene used according to the invention is obtained by chemical vapor deposition or CVD, preferably by a process using a powdery catalyst based on a mixed oxide. It is typically in the form of particles having a thickness of less than 50 nm, preferably less than 15 nm, more preferably less than 5 nm and less than one micron lateral dimensions, preferably from 10 nm to less than 1000 nm, more preferably from 50 to 600 nm, or even from 100 to 400 nm. Each of these particles generally contains from 1 to 50 sheets, preferably from 1 to 20 sheets and more preferably from 1 to 10 sheets, or even from 1 to 5 sheets which are capable of being disconnected from one another in the form of independent leaflets, for example during an ultrasound treatment.
• Carbon black is a colloidal carbon material manufactured industrially by incomplete combustion of heavy petroleum products, which is in the form of carbon spheres and aggregates of these spheres and whose dimensions are generally between 10 and 1000 nm.
• the process according to the invention makes it possible to disperse efficiently and homogeneously a large quantity of carbon nanofillers in the sulfur-containing material.
• the carbon nanofillers are thus homogeneously dispersed throughout the mass of the particles, and are not found only on the surface of the sulfur particles as described in document FR 2 948 233.
• an additive modifying the rheology of the sulfur-containing material such as sulfur in the molten state, in order to reduce the self-heating of the mixture in the compounding device.
• additives having a fluidifying effect on liquid sulfur are described in application WO 2013/178930. Examples that may be mentioned include dimethyl sulphide, diethyl sulphide, dipropyl sulphide, dibutyl sulphide, dimethyl disulphide, diethyl disulphide, dipropyl disulphide, dibutyl disulphide, and the like. trisulfides, their tetrasulfide counterparts, their pentasulfide counterparts, their hexasulfide counterparts, alone or as mixtures of two or more of them in all proportions.
• the amount of rheology modifying additive is generally from 0.01% to 5% by weight, preferably from 0.1% to 3% by weight relative to the total weight of the masterbatch.
• at least one additive may be introduced into the compounding device. The nature of the additive will be adapted to the end use of the ready-to-use masterbatch.
• additives are, for example, accelerators or vulcanization activators, lubricants, pigments, stabilizers, fillers or reinforcements, antistatic agents, fungicides, flame retardants, solvents, ionic conductors, binders, without this list being exhaustive.
• the masterbatch is in physical form agglomerated, for example in the form of granules.
• the masterbatch can be subjected to a grinding step according to techniques well known to those skilled in the art, so as to obtain a masterbatch in powder form.
• a grinding step according to techniques well known to those skilled in the art, so as to obtain a masterbatch in powder form.
• a hammer mill, a ball mill, an air jet mill, or a planetary mixer may be used.
• the median diameter D50 sought will be dependent on the use of the masterbatch, generally between 1 and 60 ⁇ , preferably between 10 and 50 ⁇ , preferably between 10 and 20 ⁇ .
• a masterbatch is obtained having carbon nanofillers well dispersed in the mass of the particles. This morphology can be verified in particular by observation with a transmission electron microscope or with a scanning electron microscope.
• the invention thus relates to a solid composition
• a solid composition comprising from 0.01 to 50% by weight, preferably from 1 to 30% by weight, and more preferably from 5 to 25% by weight of carbon nanofillers dispersed in a sulfur-containing material. .
• the solid composition may further comprise at least one additive selected from rheology modifiers, vulcanization accelerators or activators, lubricants, pigments, stabilizers, fillers or reinforcements, antistatic agents, fungicides, flame retardants, solvents, ionic conductors, or binders, or their combination.
• the solid composition can be obtained according to the method described above and can be in powder form after grinding.
• the powder has particles having a median diameter D 50 of between 1 and 60 ⁇ , preferably between 10 and 50 ⁇ .
• composition according to the invention is advantageously used for the manufacture of body seals or sealing, tires, noise plates, static dissipators, internal conductive layer for high and medium voltage cables, or anti-vibration systems such as automobile shock absorbers, or in the manufacture of structural elements of bulletproof vests, or for the manufacture of electrodes for Li / S batteries or supercapacitors.
• the masterbatch that can be obtained according to the process according to the invention or the solid composition according to the invention can be used in conventional sulfur or more generally sulfur-containing materials, but also makes it possible to develop new applications requiring reinforcement. mechanical or electronic conductivity brought by the presence of carbon nanofillers within the sulfur material.
• CNTs Graphistrength ® Cl 00 AR EMA
• solid sulfur 50- 800 ⁇
• Temperature setpoints within the co-kneader were as follows: Zone 1: 140 ° C; Zone 2: 130 ° C; Screw: 120 ° C.
• the masterbatch consisting of 85% by weight of sulfur and 15% by weight of CNT is in the form of granules obtained by cutting at the top, cooled by a jet of water. Observation using a scanning electron microscope (SEM) showed that CNTs were well dispersed in sulfur ( Figure 1). The granules obtained were dried to a moisture content ⁇ 100 ppm.
• the dry granules were then milled in a hammer mill, cooling being provided by nitrogen.
• FIG. 2 represents the distribution of the particle size of the powder and shows the absence of particles larger than 50 ⁇ , making it possible to avoid the formation of defects when using this powder for the production of cathodes of Li / S batteries.
• Figure 3 shows by scanning electron microscopy the homogeneous morphology in the mass of a particle.
• This powder consisting of 85% by weight of sulfur and 15% by weight of CNT can be used, for example, for the preparation of a Li / S battery electrode active substance, or of an EPDM base formulation for the application of profiled products. in the automotive field.
• CNTs Graphistrength ® Cl 00 from ARKEMA
• solid sulfur 50-800 ⁇
• DMDS Liquid dimethyl disulfide
• Temperature setpoints within the co-kneader were as follows: Zone 1: 140 ° C; Zone 2: 130 ° C; Screw: 120 ° C.
• the masterbatch consisting of 78% by weight of sulfur, 2% by weight of DMDS and 20% by weight of CNT is in the form of granules obtained by cutting at the top, cooled by a jet of d 'water.
• the granules obtained were dried to a moisture content ⁇ 100 ppm.
• the dry granules were then milled in a hammer mill, cooling being provided by nitrogen.
• Example 3 Preparation of a masterbatch S / disulphide of poly (tert-butyl phenol) / NTC
• DMDS Liquid dimethyl disulfide
• Poly disulfide (tert-butyl phenol) sold under the name ® VULTAC- TB7 Arkema was premixed with a Li salt, sold under the name LOA (Lithium 4,5-dicyano-2- (trifluoromethyl) imidazole) by Arkema then introduced into the first hopper using a 3 rd doser.
• LOA Lithium 4,5-dicyano-2- (trifluoromethyl) imidazole
• Temperature setpoints within the co-kneader were as follows: Zone 1: 140 ° C; Zone 2: 130 ° C; Screw: 120 ° C.
• the mixture is in the form of granules obtained by cutting at the head, cooled by a jet of water.
• the granules obtained were dried to a moisture content ⁇ 100 ppm.
• the dry granules were then milled in a hammer mill, cooling being provided by nitrogen.
• Poly disulfide (tert-butyl phenol) sold under the name VULTAC- TB7 Arkema ® was premixed with solid sulfur and acid stearique and ZnO in the form of powder, then introduced into the first hopper by the second metering device.
• Temperature setpoints within the co-kneader were as follows: Zone 1: 140 ° C; Zone 2: 130 ° C; Screw: 120 ° C.
• the masterbatch consisting of 20 wt% sulfur, 20% CNT, 20% Vultac TB7 ®, 15% stearic acid and 25% of ZnO, in the form of granules obtained by cutting in the head, cooled by a jet of water.
• the granules obtained were dried to a moisture content ⁇ 100 ppm.
• This masterbatch can be used as a vulcanizing agent for the manufacture of automobile dampers.

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