LIGNIN-ENHANCED BUTYL RUBBERS

Abstract

Halogenated butyl rubbers are provided comprising lignins and co-reinforcing agents, where the ratio of the lignin to the co-reinforcing agent is selected so as to effectively modulate advantageous properties of the vulcanizate. The advantageous properties are achieved when using a ratio of lignin to the co-reinforcing agent, such as carbon black or silica, that is higher than in a reference vulcanizate, in effect the substitution of lignin for conventional reinforcing agents improves the reinforcement of the vulcanizates.

Claims

1. A lignin-reinforced vulcanizate comprising: an elastomer comprising a synthetic halogenated poly(isobutene-co-isoprene) butyl rubber (XIIR), the XIIR being a copolymer of 95-99.5% isobutylene and 0.5-5% isoprene; a co-reinforcing agent in a co-reinforcing concentration that increases the tensile strength of the vulcanizate compared to a reference vulcanizate, the co-reinforcing agent being carbon black or silica or a mixture thereof, and the co-reinforcing agent making up from 10-80 parts per hundred rubber (phr); a lignin in a lignin concentration making up from 1-40 phr that increases crosslinking in the vulcanizate and: increases one or more of the tensile strength, elongation at break, a tensile modulus, or crack growth resistance; and/or decreases air permeability; of the vulcanizate compared to the reference vulcanizate; wherein the ratio of the lignin to the reinforcing agent is higher in the vulcanizate than in the reference vulcanizate, and the co-reinforcing concentration of the co-reinforcing agent in the vulcanizate is equal to or higher than a reference concentration of the co-reinforcing agent in the reference vulcanizate.

2. The lignin-reinforced vulcanizate of claim 1, wherein the vulcanizate comprises a phenolic component, and the lignin constitutes substantially all of the phenolic component of the vulcanizate.

3. The lignin-reinforced vulcanizate of claim 1, further comprising a filler that is a calcium carbonate, kaolin clay, talc, barite, or diatomite.

4. The lignin-reinforced vulcanizate of claim 1, wherein the co-reinforcing agent is carbon black, silica or a mixture of carbon black and silica.

5. The lignin-reinforced vulcanizate of claim 1, wherein the tensile modulus is a 50% tensile modulus, 100% tensile modulus, 200% tensile modulus, or 300% tensile modulus.

6. The lignin-reinforced vulcanizate of claim 1, wherein the elastomer comprises 98-99% isobutylene and 1-2% isoprene.

7. The lignin-reinforced vulcanizate of claim 1, wherein the lignin is derived in whole or in part from hardwood biomass, from softwood biomass or from annual fibre biomass.

8. The lignin-reinforced vulcanizate of claim 1, wherein the lignin is provided in a pelletized form.

9. The lignin-reinforced vulcanizate of claim 1, wherein the lignin contains between about 10 wt % and about 50 wt % moisture.

10. The lignin-reinforced vulcanizate of claim 1, wherein the co-reinforcing concentration of the co-reinforcing agent in the vulcanizate is equal to or higher than the reference concentration of the co-reinforcing agent in the reference vulcanizate.

11. A process for making a lignin-reinforced vulcanizate, comprising: providing an elastomer comprising a halogenated poly(isobutene-co-isoprene) butyl rubber (XIIR), the XIIR being a copolymer of 95-99.5% isobutylene and 0.5-5% isoprene; admixing the XIIR with a co-reinforcing agent and a lignin, wherein: the co-reinforcing agent is provided in a co-reinforcing concentration that increases the tensile strength of the vulcanizate compared to a reference vulcanizate, the co-reinforcing agent being carbon black or silica or a mixture thereof, and the co-reinforcing agent making up from 10-80 parts per hundred rubber (phr); the lignin is provided in a lignin concentration making up from 1-40 phr that increases crosslinking in the vulcanizate and: increases one or more of the tensile strength, elongation at break, a tensile modulus, or crack growth resistance; and/or decreases air permeability; of the vulcanizate compared to the reference vulcanizate; wherein the ratio of the lignin to the reinforcing agent is higher in the vulcanizate than in the reference vulcanizate, and the co-reinforcing concentration of the co-reinforcing agent in the vulcanizate is equal to or higher than a reference concentration of the co-reinforcing agent in the reference vulcanizate; and, adding an effective amount of a vulcanizing agent to the admixed XIIR, co-reinforcing agent and lignin, under reaction conditions that provide the lignin-reinforced vulcanizate.

12. The process of claim 11, wherein vulcanizate comprises a phenolic component, and the lignin constitutes substantially all of the phenolic component of the vulcanizate.

13. The process of claim 11, further comprising adding a filler that is a calcium carbonate, kaolin clay, talc, barite, or diatomite.

14. The process of claim 11, wherein the co-reinforcing agent is carbon black, silica or a mixture of carbon black and silica.

15. The process of claim 11, wherein the tensile modulus is a 50% tensile modulus, 100% tensile modulus, 200% tensile modulus, or 300% tensile modulus.

16. The process of claim 11, wherein the elastomer comprises 98-99% isobutylene and 1-2% isoprene.

17. The process of claim 11, wherein the lignin is derived in whole or in part from hardwood biomass, from softwood biomass or from annual fibre biomass.

18. The process of claim 11, wherein the lignin is provided in a pelletized form.

19. The process of claim 11, wherein the vulcanizate is formulated by direct mixing of the lignin with the XIIR, without co-precipitation of the lignin with the XIIR.

20. The process of claim 11, wherein the co-reinforcing concentration of the co-reinforcing agent in the vulcanizate is equal to or higher than the reference concentration of the co-reinforcing agent in the reference vulcanizate.

Description

DETAILED DESCRIPTION

[0019] Halogenated butyl rubbers (XIIRs) for use in the present formulations may comprise copolymers of isobutylene (for example 95-99.5 weight percent, or 98-99 wt %) and isoprene (for example 0.5-5 wt %, 0.3-6 wt % or 1-2 wt %, see Kruzelak & Hudec, 2018, Rubber Chem & Technology, 91 (1) 167-183). Chlorobutyl XIIRs may for example contain chlorine in an amount of from about 0.1 to about 6 wt %, or from about 0.8 to about 1.5 wt %. Bromobutyl XIIRs may for example contain bromine in an amount of from about 0.1 to about 15 wt %, or from about 1 to about 6 wt %. In halogenated butyl rubbers, the halogen content is limited by the isoprene content, and further limited by the characteristic that, in general, only a portion of the double bonds are halogenated, typically about 60%. Butyl rubber is typically produced by the cationic copolymerization of isobutylene with isoprene in the presence of a Friedel-Crafts catalyst at low temperature, for example around −100° C. or −90° C. The halogenated butyl rubber may then be produced, for example, by reacting a hexane solution of butyl rubber with elemental bromine or chlorine (K. Matyjaszewski, Cationic Polymerizations: Mechanisms, Synthesis & Applications, 1996).

[0020] The reinforced halogenated butyl rubber provided herein may be prepared by a wide range of methods, as for example described in ASTM D3958 and ASTM D3182. The XIIR may for example be mixed with lignins and co-reinforcing agents, such as carbon black and/or silica, on masticating equipment such as a rubber mill. Alternatively, the XIIR may be dissolved in a solvent, such as cyclohexane, and reinforcing agents added to the solution followed by mixing.

[0021] Carbon blacks for use in the reinforced XIIR may for example be of a grade designated according to ASTM D 1765 as N300 to N900 series, or specifically N650, N375, N347, N339, N330 (alternatively including others, such as N220 or N110).

[0022] Suitable amounts of carbon black or silica which may be used as reinforcing agents are from about 5 to about 70 parts per hundred rubber (phr), or from about 30 to about 50 phr.

[0023] Formulations may include cure activators or dispersing agents such as stearic acid (as exemplified), as well other processing aids such as, for example, naphthenic oil. A processing aid, emulsifier or dispersing agent may for example be an ammonium or alkali metal salt of C.sub.12-24 fatty acids, such as ammonium, sodium or potassium salts of oleic acid, palmitic acid, stearic acid or linoleic acid. Alternative dispersing agents include ammonium and alkali metal salts of polyethoxylated sulfates of C.sub.6-20 alkyl alcohols, or polyethoxylated C.sub.6-14 alkylphenoxy ethanols, and acid esters (phthalic, adipinic, phosphoric, for example at loadings of 5-15 and 5-30 phr). Suitable amounts of the emulsifier may for example be from about 0.1 to about 15 phr, or from about 0.1 to about 5 phr.

[0024] Reinforced XIIRs may be formulated with the assistance of vulcanization reactants, activators, catalysts or accelerators, such as ZnO and/or sulfur and/or accelerator activators and/or sulfur donor/accelerators, such as: thiazoles, sulfenamides, guanidines, dithiocarbamates and thiuram sulfides; for example, thiocarbamamyls, dithiocarbamyls, alkoxythio carbonyls, dialkylthio phosphoryls, diamino-2,4,6-triazinyls, thiurams xanthates, and/or alkylphenols. A select thiazole is 2,2-dibenzothiazyl disulfide (MBTS) and a select thiuram is tetramethyl thiuram monosulfide (TMTM). A select alkylphenol is poly-tert-amylphenoldisulfide. When used, suitable accelerators may for example be added in an amount of from about 0.1 to about 10 phr, or from about 0.1 to about 5 phr.

[0025] A wide variety of derivatives of native lignin may be used in alternative embodiments, particularly lignins recovered during or after pulping of lignocellulosic feedstocks. The lignocellulosic feedstock may for example include hardwoods, softwoods, annual fibres, and combinations thereof. The lignin may for example be produced by a process comprising: solvent extraction of finely ground wood; acidic dioxane extraction of wood; biomass pre-treatment using steam explosion, dilute acid hydrolysis, ammonia fibre expansion, or autohydrolysis; pulping of lignocellulosics by Kraft pulping, soda pulping, sulphite pulping, ethanol/solvent pulping, alkaline sulphite anthraquinone methanol pulping, methanol pulping followed by methanol NaOH and anthraquinone pulping, acetic acid/hydrochloric acid or formic acid pulping, or high-boiling solvent pulping.

[0026] In some embodiments, formulations may achieve the desired properties while lacking added phenolic resins, such as resins of the kind used as reinforcing agents or tackifiers, or other crosslinking agents such as hexamine. Accordingly, where the vulcanizate comprises a phenolic component, the lignin may constitute substantially all of the phenolic component of the vulcanizate. Alternatively, the lignin may for example constitute at least about 45%, about 50%, about 55%, about 60%, about 65%, about &0%, about 75%, about 80%, about 85%, about 90%, about 95% or about 99% of the phenolic component of the vulcanizate, or any amount therebetween. In various embodiments, the lignin may constitute about 50% of the phenolic component of the vulcanizate. In other embodiments, the lignin may constitute about 75% to about 99% of the phenolic component of the vulcanizate, or any amount therebetween.

[0027] In various embodiments, moisture content may have an impact on lignin-containing vulcanizate performance. For example, increasing moisture content of the lignin in the vulcanizate may improve tensile properties, such as, for example, improve compound stiffness. The moisture content of the lignin may be between 0 wt % and about 300 wt % or any content therebetween. In various embodiments, the moisture content of the lignin may be between about 3 wt % and about 100 wt %, or any amount therebetween. In various embodiments, the moisture content of the lignin may be between about 10 wt % and about 50 wt % or any amount therebetween.

EXAMPLES

[0028] The following Examples demonstrate characteristics of selected embodiments, illustrating for example that similar mechanical performance (equivalent tensile strengths and slightly increased tensile moduli) may be obtained in a lignin-reinforced XIIR, compared to exclusive use of a general purpose carbon black (N660) as a reinforcing agent, with partial carbon black replacement (<50%) with lignin in a simple BIIR system with a ZnO only cure. Surprisingly, when lignin replaces a higher reinforcing grade of carbon black (N330) in such formulations, the reinforcing effect is more pronounced. These characteristics illustrate the ability to tune the lignin-reinforced XIIR vulcanizates by adjusting the ratio of lignin to co-reinforcing agent.

[0029] In contrast to the effect in lignin-reinforced XIIR systems, when lignin is applied as a partial carbon black replacement in a simple NR system with a conventional sulfur cure, similar tensile strengths but increased % elongation (with a corresponding drop in tensile modulus) is obtained in the cured vulcanizates.

[0030] In a more complex BIIR/NR co-formulation, prepared with ZnO, sulfur donors and accelerators, the partial replacement of a reinforcing grade carbon black (N330) by lignin results in an unexpected enhancement of the vulcanizate properties, specifically a torque increase during curing, as well as the tensile modulus/stiffness. NMR and solvent swelling tests confirm a greater degree of crosslinking in the sample containing lignin, providing a mechanistic explanation for the empirically observed enhancement of selected vulcanizate properties.

[0031] The Examples further demonstrate that by making adjustments in the cure package of the complex BIIR/NR formulation, the properties of the vulcanizate containing lignin can be adjusted, or tuned, to significantly improve the crack growth performance of these compounds, relative to the control without lignin. It is also demonstrated that when lignin is present in selected amounts, the mechanical properties of the vulcanizate are maintained—even when the cure chemical loading is reduced to 50% of the original loading.

[0032] The following Examples further illustrate an additional avenue for tuning the properties of a lignin-containing XIIR vulcanizate, through the use of alternative lignins. By comparing the effect of different lignin types in a reinforced XIIR formulation, it is shown that different lignin types influence the performance to different extents. This illustrates that adaptations of lignin-reinforcing may be accomplished through the use of alternative lignins, without the requirement to chemically modify a particular lignin, for example by selecting a lignin evidencing greater reactivity in a particular formulation. For example, lignins may be selected based on the abundance of particular phenyl propanoid units, particularly the coniferyl alcohol, sinapyl alcohol and coumaryl alcohol units, which corresponds to guaiacyl (G), syringyl (S) and p-hydroxyphenyl (H) lignin structures.

[0033] The use of different physical forms of lignin are also exemplified, powder and pellets, demonstrating that similar or even slightly improved performance can be obtained when using pelletized lignin. This is significant because pelletized lignin may be a more practical option for dry/direct mixing in a commercial context, as it creates less dust which may be important from a health and safety perspective.

[0034] Although various embodiments of the invention are disclosed herein, many adaptations and modifications may be made within the scope of the invention in accordance with the common general knowledge of those skilled in this art. Such modifications include the substitution of known equivalents for any aspect of the invention in order to achieve the same result in substantially the same way. Numeric ranges are inclusive of the numbers defining the range. The word “comprising” is used herein as an open-ended term, substantially equivalent to the phrase “including, but not limited to”, and the word “comprises” has a corresponding meaning. As used herein, the singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a thing” includes more than one such thing. Citation of references herein is not an admission that such references are prior art to the present invention. Any priority document(s) and all publications, including but not limited to patents and patent applications, cited in this specification are incorporated herein by reference as if each individual publication were specifically and individually indicated to be incorporated by reference herein and as though fully set forth herein. The invention includes all embodiments and variations substantially as hereinbefore described and with reference to the examples and drawings.

Example 1

[0035] Lignin performance in BIIR with a ZnO cure

[0036] This example illustrates the performance of lignin in a standard bromobutyl rubber (BIIR) formulation with a simple ZnO cure. Rubber formulations were prepared according to ASTM D3958, with components shown in Table 1.

TABLE-US-00001 TABLE 1 BIIR Formulation with a ZnO cure containing different lignin loadings and carbon black types Compound A B C D E F G H I Bromobutyl 100 100 100 100 100 100 100 100 100 (X_Butyl BB_2030) N660 40 32 30 24 20 10 — — — N330 — — — — — — 40 30 30 Stearic acid 1 1 1 1 1 1 1 1 1 Lignin 1 — 8 10 16 20 30 — — 10 ZnO 5 5 5 5 5 5 5 5 5

[0037] The exemplified formulations were processed according to ASTM D3182. Specifically, a 2-stage process was used involving an internal mixer and a standard two roll mill. The first stage of mixing (67° C. starting temperature) consisted of first charging the bromobutyl rubber (BIIR, X_Butyl™ BB2030, halogen content 1.80 wt %) to the internal mixer and ram down mixing for 30 seconds. The carbon black, lignin and stearic acid were then added, the ram lowered and mixed to an accumulative time of between 5-7 minutes. The batch was discharged at a temperature of 138° C. The batch was immediately passed through a standard laboratory mill three times, set at 0.25 in and 50° C. During the second stage of mixing, the ZnO was charged along with the masterbatch to the internal mixer and mixed until a temperature of 93° C. was reached. The batch was then discharged and immediately milled (50° C. and 0.032 in. opening) followed by a set of 4 passes through an opening of 0.25 in, folding the material back on itself and alternating the grain direction.

[0038] Table 2 shows that the partial replacement of carbon black by lignin has very little impact on the extent of rubber curing, albeit a slight plasticizing effect (lower minimum torque) and increase in delta torque being observed.

TABLE-US-00002 TABLE 2 Rheological data of BIIR with a ZnO cure Compound A B Min Torque (ML), lbf-inch 12.13 11.46 Max Torque (MH), lbf-inch 23.05 25.59 Delta Torque 10.92 14.13

[0039] There was little to no impact on the physical properties of the resulting vulcanizates containing lignin for replacements up to 40% of a carcass grade (N660) carbon black (Table 3, D). At higher lignin loadings, the mechanical properties generally decrease (Table 3, E), however based on the tensile moduli at 50-100% elongations, some measure of reinforcement is observed. (Table 3, A vs E). When lignin replaces a reinforcing/tread grade of carbon black (N330), a more significant increase in the tensile moduli is observed with lignin relative to control (Table 3, I vs G), with a corresponding decrease in the ultimate % elongation. This indicates that stiffer vulcanizates can be obtained with lignin, especially when replacing a reinforcing grade of carbon black. Furthermore, a comparative sample with similar carbon black content but without the lignin, has significantly lower tensile moduli (Table 3, H).

TABLE-US-00003 TABLE 3 Physical Properties of BIIR rubber cured using a ZnO system Compound A B C D E F G H I Tensile strength (psi) 1269 1283 1237 1172 1009 862 1502 1420 1404 Elongation at break (%) 662 647 675 705 737 858 624 729 595 50% Modulus (psi) 85 107 91 104 85 85 120 87 131 100% Modulus (psi) 122 165 137 157 127 124 170 117 206 200% Modulus (psi) 244 303 250 266 210 190 340 218 380 300% Modulus (psi) 434 483 404 393 298 243 592 379 605

Example 2

[0040] Lignin performance in NR compounds with a conventional sulfur cure

[0041] In this Example, standard natural rubber (NR) compounds were prepared according to the formulation in ASTM D3192 using the conditions described in Example 1 (as shown in Table 4).

TABLE-US-00004 TABLE 4 NR Formulation containing ZnO and a sulfur vulcanization system (lignin replacing carbon black) Compound J K L M N O RSS#3 100 100 100 100 100 100 N660 — 50 37.5 37.5 25 — Stearic acid 3 3 3 3 3 3 Lignin 1 — — — 12.5 25 50 ZnO 5 5 5 5 5 5 MBTS 0.6 0.6 0.6 0.6 0.6 0.6 Sulfur 2.5 2.5 2.5 2.5 2.5 2.5

[0042] Comparison of the physical properties of these compounds (shown in Table 5) indicates a different effect of lignin on the mechanical properties for NR, compared to BIIR (Example 1). When lignin is present at 25% replacement of carbon black (Table 5, M), the tensile strength is similar to that of the control, however there is an increase in the ultimate % elongation, with a corresponding decrease in the tensile moduli. The tensile moduli is however higher than that of the unfilled rubber (Table 5, J) and the compound with equivalent carbon black loading (Table 5, L). At 50% replacement, the tensile strength and moduli are significantly lower than that of the control, however still higher than that of the unfilled rubber (Table 5, J). At 100% replacement, the tensile moduli up to 300% elongation are significantly higher than that of the unfilled rubber, however the tensile strength at break and ultimate % elongation are reduced.

TABLE-US-00005 TABLE 5 Physical properties of NR cured with a conventional sulfur (CV) system Compound J K L M N O Tensile strength (psi) 2821 3649 3933 3683 3222 2090 Elongation at break (%) 817 452 552 541 582 513 50% Modulus (psi) 75 204 150 176 145 145 100% Modulus (psi) 113 418 282 351 270 255 200% Modulus (psi) 182 1141 747 835 616 523 300% Modulus (psi) 269 2096 1461 1496 1074 861

Example 3

[0043] Lignin performance in a BIIR/NR formulation with a semi-efficient cure

[0044] In this Example, the complementary effects of lignin in the respective BIIR and NR systems is demonstrated. A combined BIIR/NR system with a more complex cure package, including sulfur donors and accelerators, in addition to ZnO, were prepared (Table 6) and processed as per Example 1. However, in this Example, during the second stage of mixing, ZnO, TMTM, MBTS and Vultac 5 were charged along with the masterbatch to the internal mixer and mixed until a temperature of 93° C. was reached. The batch was then discharged and immediately milled (50° C. and 0.032 in. opening) followed by a set of 4 passes through an opening of 0.25 in, folding the material back on itself and alternating the grain direction.

[0045] Table 6 illustrates the composition of the different lignin compounds (Q and R), relative to the control (P). For compound Q, 20% of the N330 carbon black was replaced by lignin, whereas in compound R, 20% of the clay was replaced by lignin in addition to the carbon black replacement, resulting in a total lignin loading of 16 phr.

TABLE-US-00006 TABLE 6 BIIR/NR formulation containing ZnO and semi-efficient sulfur vulcanization system (lignin replacing carbon black) Compound P Q R Bromobutyl BB2030 80 80 80 RSS #3 20 20 20 N330 40 32 32 Soft Clay 40 40 32 Stearic acid 1 1 1 Napthtenic Oil 10 10 10 Lignin 1 — 8 16 ZnO 5 5 5 TMTM 0.25 0.25 0.25 MBTS 1.25 1.25 1.25 Vultac 5 0.5 0.5 0.5

[0046] In this formulation, the curing process of the rubber vulcanizates were significantly affected. In contrast to the basic ASTM formulation, a significant increase in both the minimum and maximum torque, as well as the delta torque for the lignin samples (Q and R), was observed relative to the control without lignin (P) (Table 7). The minimum and maximum torque values were slightly higher for the higher lignin loading (R), however the torque difference was similar for the two different lignin loadings.

TABLE-US-00007 TABLE 7 Rheological data for BIIR/NR compounds with the ZnO and semi-efficient sulfur cure system Compound P Q R Min Torque (ML), lbf-inch  8.27 10.94 13.04 Max Torque (MH), lbf-inch 22.73 32.84 34.79 Delta Torque 14.46 21.9  21.8 

[0047] Mechanical test data showed a significant increase in the stiffness (moduli) of the compounds (Q and R) at different strains, along with a slight reduction in the elongation (Table 8). The tensile strengths are however comparable to the vulcanizate without lignin (P) and full CB loading. Furthermore, the effect of increased stiffness was more pronounced as the strain increases up to 200% (Q) and 300% (R).

[0048] Both vulcanizates containing lignin (Q and R) have improved (lower) air permeability values than the control (P), which is beneficial for certain applications such as inner-liners. The double partial replacement of carbon black and clay (R), exemplified the best balance in terms of air impermeability and crack growth resistance within the limits of experimental variability. This illustrates that lignins can be substituted for both reinforcing fillers, such as carbon black and silica, and for non-reinforcing fillers, such as clays, in XIIR vulcanizates, while improving the air impermeability of the compound. Furthermore, as the density of lignin is significantly lower than that of clay (typically about half), this facilitates the production of light-weighting vulcanizates having improved properties.

TABLE-US-00008 TABLE 8 Physical Properties for BIIR/NR vulcanizates with the semi-efficient cure Compound P Q R Tensile strength (psi)   1394   1441   1421 Elongation at break (%)    657    562    549  50% Modulus (psi)    112    144    141 100% Modulus (psi)    168    251    247 200% Modulus (psi)    300    479    495 300% Modulus (psi)    476    733    773 Crack growth 385 000 110 000 305 000 (cycles to 0.5″ crack growth) Air permeability (L/m.sup.2*24 hr)        0.100         0.0452         0.07035

TABLE-US-00009 TABLE 9 Crosslink densities for lignin compounds produced with different rubber types and cure systems Compound G I J K L M P Q Crosslink density 0.83 1.09 3.44 6.37 5.09 5.23 1.46 2.30 (× 10.sup.-5 mol/cm.sup.3)

[0049] Crosslink densities were determined by solvent swelling in n-decane as described by Boonkerd et al. (2016). The crosslink density results support the observations for the tensile moduli. Comparing the crosslink densities (XLD) for the BIIR/ZnO compounds, a slight increase in the XLD in the presence of lignin (Table 9, I), was observed compared to the control (Table 9, G). For a NR/CV cure the 25% EKL replacement (Table 9, M) shows a slightly higher crosslink density than the corresponding sample with equivalent carbon black (Table 9, L) or unfilled sample (Table 9, J), but lower than that of the control (Table 9, K). In the formulation with an 80/20 BIIR/NR composition and with a sulfur donor, the crosslink densities are significantly increased in the presence of lignin (Table 9, Q vs P).

Example 4

[0050] Effect of Rubber Composition on Properties

[0051] In this Example, the stiffness increase observed with lignin is shown to be unique to the specific combination of rubber types in the inner-liner formulation. Table 10 shows the comparative samples for formulations containing either 100 phr BIIR without lignin (S) or with lignin (T) or 100 phr NR without lignin (U) and with lignin (V). Comparing the tensile properties of these compounds relative to the specific inner-liner formulation containing 80 phr BIIR and 20 phr NR (Table 6, P and Q), it is evident that lignin does not provide a benefit in either of the 100 phr BIIR and 100 phr NR systems (Table 11). For the 100 phr BIIR system, the tensile properties obtained with lignin is the same as those without and for the 100 phr NR system, the tensile properties, particularly the stiffness, is reduced in the presence of lignin.

TABLE-US-00010 TABLE 10 Formulation containing a semi-efficient vulcanization system with different rubber compositions) Compound S T U V Bromobutyl BB2030 100 100 RSS #3 100 100 N330 40 32 40 32 Soft Clay 40 40 40 40 Stearic acid 1 1 1 1 Napthtenic Oil 10 10 10 10 Lignin 1 (HKL) 8 8 ZnO 5 5 5 5 TMTM 0.25 0.25 0.25 0.25 MBTS 1.25 1.25 1.25 1.25 Vultac 5 0.5 0.5 0.5 0.5

TABLE-US-00011 TABLE 11 Effect of rubber composition on properties Compound S T U V Tensile strength (psi) 1475 1423 1108 851 Elongation at break (%)  704  669  485 469  50% Modulus (psi)  164  148  87  75 100% Modulus (psi)  229  231  146 123 200% Modulus (psi)  382  393  328 269 300% Modulus (psi)  575  571  572 461

Example 5

[0052] Lignin Replacement of Additional Cure Components

[0053] The increased degree of crosslinking, tensile moduli and increase in delta torque, as disclosed in Example 3, is indicative of interactions between lignin and the cure system. To further illustrate the surprising performance of lignin in semi-efficient vulcanization systems, embodiments are exemplified in this Example with the removal/reduction of various cure chemicals, as shown in Table 12.

TABLE-US-00012 TABLE 12 Formulation containing semi-efficient vulcanization system (lignin replacing carbon black and removal/reduction of cure chemicals) Compound P W X W1 W1 + X Bromobutyl BB2030 80 80 80 80 80 RSS #3 20 20 20 20 20 N330 40 32 32 32 32 Soft Clay 40 40 40 40 40 Stearic acid 1 1 1 1 1 Napthtenic Oil 10 10 10 10 10 Lignin 8 8 8 8 ZnO 5 5 2.5 5 2.5 TMTM 0.25 0.25 0.25 0.25 0.25 MBTS 1.25 1.25 1.25 1.25 1.25 Vultac 5 0.5 — 0.5 0.25 0.25

[0054] Comparing the rheological properties in Tables 13 and 14, the compounds X, W1 and W1+X achieved significantly higher maximum and delta torques than the control (P), even when up to about 50% of the curatives were removed. This illustrates a surprising role of lignin during the curing process. Complete removal of Vultac 5 (W), resulted in similar maximum torque but slightly lower delta torque. In all cases the minimum torque was higher with lignin.

TABLE-US-00013 TABLE 13 Rheological data Compound P W X Min Torque (ML)-lbf.in  8.27 10.51 10.72 Max Torque (MH)-lbf.in 22.73 21.77 32.37 Delta Torque-lbf.in 14.46 11.26 21.65

TABLE-US-00014 TABLE 14 Rheological data collected using an MDR with 0.5° arc Compound P W1 X W1 +X Min Torque (ML)-lbf.in 1.21 1.24 1.26 1.32 Max Torque (MH)-lbf.in 3.48 3.91 4.79 4.12 Delta Torque-lbf.in 2.27 2.67 3.53 2.80

[0055] The mechanical properties of the vulcanizates are shown in Table 15. Note that even though compound W has a lower ultimate tensile strength than the control (P), its fatigue performance (crack growth resistance) is significantly improved, which is important for applications that require resilience e.g. inner-liners. In addition to the improved fatigue performance, compound W is also stiffer than compound P, for elongations up to 300%. This represents the most extreme case of a complete removal of the primary curative, i.e. the sulfur donor. Improved resistance to deformation (stiffness/tensile moduli) along with improved fatigue performance is a unique balance of properties achievable with the use of a lignin in combination with a co-reinforcing agent, as these two properties are normally inversely related. The air permeability of this compound is, however, significantly increased.

[0056] Furthermore, when lignin is present in the compounds, 50% of each of the cure chemicals could be removed without any negative effects on mechanical stiffness (Table 15-W1, X and W1+X). In fact, consistent with the delta torque increase, these compounds have superior tensile moduli compared to the control. While a 50% reduction in the ZnO loading (Table 15, X) doesn't improve crack growth performance or air permeability, the 50% reduction in the S-donor (Table 15, W1) significantly improves the crack growth resistance, while also improving the air permeability, compared to the compound without any S-donor (Table 15, W).

[0057] The combined reduction of S-donor and ZnO (W1+X) provides the best crack growth performance, while maintaining good air permeability. However, in this case the ultimate tensile strength is reduced to 77% of that of the original. The tensile moduli were however still higher for this lignin compound than for the control, with a corresponding decrease in the ultimate elongation, indicating a stiffer compound in the presence of lignin, with excellent crack growth resistance, even when both of the main curatives are reduced by 50%.

TABLE-US-00015 TABLE 15 Physical properties of compounds with reduced curatives loading Compound P W W1 X W1 + X Tensile strength (psi)   1394   1061   1172   1433  1072 Elongation at break (%)    657    589    587    572   583  50% Modulus (psi)    112    121    122    138   116 100% Modulus (psi)    168    193    200    241   185 200% Modulus (psi)    300    353    378    461   342 300% Modulus (psi)    476    529    575    708   518 Crack growth resistance 385 000 550 000 590 000 193 333 786667 (cycles to 0.5″ crack growth) Air permeability (L/m.sup.2*24 hr)        0.100         0.3661        0.073        0.109       0.088

Example 6

[0058] Effect of Lignin Type on a BIIR/NR Formulation with a Semi-Efficient Cure

[0059] Lignin composition can vary depending on the source (biomass) and extraction method. In this Example, the performance of different types of lignin in the BIIR/NR/semi efficient system (Table 16) is exemplified. The different lignin types are: hardwood kraft (HKL), North American softwood kraft (SKL 1), Organosolv lignin (OSL), lignosulfonate (LS) and sulfonated kraft lignin (SL). The samples were compounded and vulcanized as described above.

TABLE-US-00016 TABLE 16 Formulation containing semi-efficient vulcanization system (different lignin types replacing carbon black) Compound Y Z AA BB CC DD Bromobutyl BB2030 80 80 80 80 80 80 RSS#3 20 20 20 20 20 20 N330 40 32 32 32 32 32 Soft Clay 40 40 40 40 40 40 Stearic acid 1 1 1 1 1 1 Napthtenic Oil 10 10 10 10 10 10 Lignin 1 (HKL) 8 Lignin 2 (SKL1) 8 Lignin 3 (OSL) 8 Lignin 4 (LS) 8 Lignin 5 (SL) 8 ZnO 5 5 5 5 5 5 TMTM 0.25 0.25 0.25 0.25 0.25 0.25 MBTS 1.25 1.25 1.25 1.25 1.25 1.25 Vultac 5 0.5 0.5 0.5 0.5 0.5 0.5

[0060] The mechanical properties of these vulcanizates are shown in Table 17. The ultimate tensile strength and moduli are relatively comparable to that of the control, relative to the control, and slightly better in the presence of HKL (Z), and OSL (BB).

TABLE-US-00017 TABLE 17 Physical properties for BIIR/NR vulcanizates with the semi-efficient cure system. Compound Y Z AA BB CC DD Tensile strength (psi) 1434 1466 1306 1386 1293 1192 Elongation at break (%) 635 612 613 631 623 608 50% Modulus (psi) 144 140 137 144 117 130 100% Modulus (psi) 216 231 216 227 185 197 200% Modulus (psi) 387 430 375 412 352 340 300% Modulus (psi) 603 652 567 615 553 520

Example 7

[0061] Effect of Lignin Moisture Content and Physical Form (Lignin Pellets and Powder) on Properties

[0062] In this Example the effect of lignin moisture content (bound and free water) as well as physical form (powder and pellet) on vulcanizate performance is presented and shown in Table 18. The carbon black reference compounds without lignin (EE and FF), have similar cure and tensile properties regardless of the moisture content. Even when increasing moisture contents up to 4 phr total loading, no difference in the performance was observed. By comparison, moisture content did have an impact on lignin-containing vulcanizate performance. Samples prepared with dry lignin (GG) performed comparable to that of the carbon black only samples (EE and FF). However, in the lignin containing samples an increase in physical properties was observed in the presence of moisture. Increasing the moisture content to 10 wt % (HH) improved tensile properties, particularly improving compound stiffness. This improvement in performance was maintained when the moisture content was further increased to 100 wt % (JJ). Similar performance was also observed for other lignin types (KK and LL).

[0063] Pelletization of the lignin (1-2 mm diameter pellet) did not impact performance, with the corresponding vulcanizate prepared using lignin pellets (II) performing as well as the powder form (HH). In some embodiments, ovoid pellets have been tested, with similar results, with the large dimension up to about 10 mm and the small dimension up to about 5 mm.

TABLE-US-00018 TABLE 18 Effect of lignin physical form (pellets and powder) and moisture content on properties Compound EE FF GG HH II JJ KK LL Lignin* HKL SKL OSL Physical form Powder Pellet Powder Powder Powder Lignin content (phr) 0 0 8 8 8 8 8 8 Moisture (wt %) 0 4 0 10 10 100 25 12 Moisture (total phr) 0 1.6 0 0.8 0.8 8 2 0.96 Delta torque (dNm) 9.66 9.42 11.33 12.68 12.17 11.76 12.6 12.3 Tensile strength (psi) 1388 1463 1314 1466 1413 1334 1392 1403 Elongation at break (%) 627 629 628 612 597 518 549 608 50% Modulus (psi) 141 132 128 140 138 154 139 135 100% Modulus (psi) 212 205 207 231 228 281 240 222 200% Modulus (psi) 380 377 377 430 431 534 481 426 300% Modulus (psi) 587 598 566 652 653 775 741 650 *HKL = hardwood Kraft lignin; SKL = softwood Kraft lignin; OSL = organosolv lignin

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