Lightweight wear-resistant sole material and preparation method thereof

Abstract

The invention discloses a lightweight wear-resistant sole material and a preparation method thereof, and relates to the technical field of high polymer materials, the lightweight wear-resistant sole material comprises the following raw materials by weight: 55 parts of ethylene propylene diene monomer, 10 parts of ultra-high molecular weight polyethylene, 25 parts of a wear-resistant filler, 10 parts of a reinforcing agent, 0.5 part of stearic acid, 1 part of zinc stearate, 0.5 part of an anti-aging agent, and 1 part of a vulcanizing agent; according to the preparation of the wear-resistant filler, through a synergistic enhancement system of multi-stage aluminum powder and carbon fibers, gradient structure design and step-by-step process optimization are combined, so that the problems that in the prior art, the lightweight and mechanical properties of a sole material are difficult to balance, and the improvement of the overall mechanical properties is limited are solved; the comprehensive improvement of wear resistance, light weight and mechanical property of the sole material is realized.

Description

Technical Field

[0001] The invention relates to the technical field of polymer materials, and in particular to a lightweight and wear-resistant sole material and a preparation method thereof. Background Art

[0002] At present, the sole materials on the market include TPR, PU, ​​rubber, EVA, etc. Among them, TPR thermoplastic rubber has both the mechanical elasticity of traditional rubber and the processability of thermoplastic plastics, and is the cheapest, but the material is heavy, has poor wear and impact resistance; PU soles have high hardness, good wear resistance and good elasticity, but are expensive and easy to break; EVA soles are light, elastic, and have good impact resistance, but poor wear resistance; rubber is used for the outsole of various shoes, with good wear resistance and good anti-slip properties. However, the wear resistance and impact resistance of natural rubber are poor, and cannot meet the requirements of long-term outdoor use of military shoes.

[0003] For example, the patent with application number CN202210376432.7, a lightweight and wear-resistant sole material and a preparation method thereof, the invention relates to a lightweight and wear-resistant sole material and a preparation method thereof, comprising the following raw materials in parts by weight: 55-75 parts of ethylene propylene diene rubber, 10-15 parts of ultra-high molecular weight polyethylene, 25-35 parts of wear-resistant filler, 10-20 parts of reinforcing agent, 0.5-1.5 parts of stearic acid, 1-3 parts of zinc stearate, 0.5-2 parts of antioxidant, 1-3 parts of vulcanizing agent; adding wear-resistant filler, without affecting the weight of the sole material itself, giving it excellent wear resistance, which is a carbon-bonded carbon composite material filled with modified alumina porous ceramic material. When it is used as a filler, firstly, the alumina ceramic material itself can be used as an excellent wear-resistant filler, but it will increase the weight when used to prepare insoles, so the carbon composite material modified alumina porous ceramic filler bonded by carbon is introduced. While ensuring that it has excellent wear resistance, it reduces its own weight and is convenient to use.

[0004] Although the above solution improves the wear resistance and lightness of the sole material to a certain extent, it is difficult for a single filler to balance lightness and mechanical properties. Although it improves wear resistance, the density is relatively high, and the tensile strength and toughness are not significantly improved, and the overall mechanical properties are limited. Summary of the invention

[0005] The embodiments of the present application provide a lightweight and wear-resistant sole material and a preparation method thereof, thereby solving the problem in the prior art that it is difficult to balance the lightweight and mechanical properties of the sole material, and the overall mechanical properties are limitedly improved. Through a synergistic reinforcement system of multi-level aluminum powder and carbon fiber, combined with gradient structure design and step-by-step process optimization, a comprehensive improvement in wear resistance, lightweight and mechanical properties is achieved.

[0006] The embodiment of the present application provides a lightweight wear-resistant sole material, comprising the following raw materials in parts by weight: 55 parts of EPDM rubber, 10 parts of ultra-high molecular weight polyethylene, 25 parts of wear-resistant filler, 10 parts of reinforcing agent, 0.5 parts of stearic acid, 1 part of zinc stearate, 0.5 parts of antioxidant, and 1 part of vulcanizing agent;

[0007] The preparation of the wear-resistant filler comprises the following steps:

[0008] S1. Add aluminum powder to a 2-3.5% potassium dichromate aqueous solution, stir to obtain a slurry, then add sodium dodecyl sulfate, stir to form a foam slurry, and set aside;

[0009] The aluminum powder includes nano aluminum powder and micron aluminum powder, the particle size of the nano aluminum powder is 50-100nm, the particle size of the micron aluminum powder is 5-10μm, and the weight ratio of the nano aluminum powder to the micron aluminum powder is 3:7; the foam slurry includes nano foam slurry and micro foam slurry;

[0010] S2, adding carbon fiber and phenolic resin into water, stirring at a speed of 1000r / min for 60min to obtain slurry, then injecting the slurry into a mold, applying pressure to the mold to squeeze out water, maintaining the pressure for 30min to form a green body, then drying the green body at 75°C for 24h, then keeping it at 150°C for 1h and 180°C for 5h, grinding it into powder to obtain a carbon composite material;

[0011] S3, mixing the nano foam slurry and the micro foam slurry to form a homogeneous mixed foam slurry;

[0012] The carbon composite material is added to the foam slurry, and then negative pressure impregnation is used to fill the carbon composite material into the pores of the foam slurry to form a mixed slurry. The mixed slurry is dried at 75°C until the solvent is removed, and then cracked in a tubular furnace at 1200°C for 2 hours under nitrogen protection, and cooled to obtain a wear-resistant filler.

[0013] Furthermore, the preparation of nano foam slurry and micro foam slurry is specifically as follows:

[0014] S1.1 Add nano aluminum powder to a 2% potassium dichromate aqueous solution, stir magnetically for 6 hours, then add sodium dodecyl sulfate, stir at a high speed of 800 r / min for 8 hours to form a stable nano foam slurry;

[0015] S1.2 Add micron aluminum powder to a 3.5% potassium dichromate aqueous solution, stir magnetically for 8 hours, then add sodium dodecyl sulfate, stir at 600 r / min for 10 hours to form a micron foam slurry.

[0016] Further, in step S1.1, the weight ratio of nano-aluminum powder, potassium dichromate aqueous solution and sodium dodecyl sulfate is 1.5:10:0.05;

[0017] In step S1.2, the weight ratio of micron aluminum powder, potassium dichromate aqueous solution and sodium dodecyl sulfate is 3:10:0.07.

[0018] Furthermore, in step S3, the micron foam slurry and the nano foam slurry are injected in layers to form a gradient foam slurry.

[0019] Furthermore, the layered injection is specifically as follows: injecting the micron foam slurry into the bottom layer of the mold and stirring at a low speed of 500r / min for 5 minutes; injecting the nano foam slurry into the surface layer and simultaneously applying a high-speed shear force of 800r / min for 10 minutes; applying a medium speed of 600r / min at the interface and stirring for 5 minutes to form a gradient foam slurry.

[0020] Furthermore, in step S2, the carbon fiber also includes long-cut viscose-based carbon fiber, wherein the short-cut viscose-based carbon fiber is 1-3 mm, and the long-cut viscose-based carbon fiber is 5-8 mm.

[0021] Furthermore, the weight ratio of the short-cut viscose-based carbon fiber to the long-cut viscose-based carbon fiber is 7:3.

[0022] Furthermore, the short-cut viscose-based carbon fibers and the long-cut viscose-based carbon fibers are pretreated respectively to obtain short-carbon composite materials and long-carbon composite materials.

[0023] Furthermore, in step S3, the short carbon composite material is injected with micron foam slurry, and the long carbon composite material is injected with nano foam slurry.

[0024] A method for preparing a lightweight and wear-resistant sole material comprises the following steps:

[0025] A1. Mix EPDM rubber, ultra-high molecular weight polyethylene, wear-resistant filler and reinforcing agent evenly, pour into internal mixer, and mix at 100℃ for 10 minutes;

[0026] A2. Add stearic acid, zinc stearate and antioxidant, raise the temperature to 120°C, continue mixing for 10 minutes to obtain a mixed rubber, add a vulcanizing agent and vulcanize at 150°C for 5 minutes. After the vulcanization, melt granulate and compression mold at a pressure of 15 MPa for 5 minutes to obtain a wear-resistant sole material.

[0027] One or more technical solutions provided in the embodiments of the present application have at least the following technical effects or advantages:

[0028] First, by introducing aluminum powders of nanometer and micrometer particle sizes, a synergistic effect is produced. Nano aluminum powder has a high specific surface area and activity, can fill micrometer-level pores, reduce interface defects, and densify the surface, thereby reducing the amount of wear. In the preparation of wear-resistant fillers, nano aluminum powder can be more evenly dispersed in the matrix material to form more interface bonding points, thereby improving the overall strength and wear resistance of the material; the macroporous structure formed by micron aluminum powder can effectively absorb impact energy, buffer impact, avoid stress concentration, and improve the impact resistance of the material;

[0029] Secondly, by adopting a layered method of injecting micron foam slurry into the bottom layer and nano foam slurry into the surface layer, a gradient structure is formed, so that when the material is subjected to external force, each layer can work together to disperse and absorb energy layer by layer. The bottom layer adopts loose and porous micro foam slurry, which is conducive to absorbing and dispersing impact energy, reducing local stress concentration, and improving impact resistance and comfort; the surface layer adopts dense and wear-resistant nano foam slurry, which can resist wear and scratches. The gradient structure optimizes the load transfer path, the surface layer bears tensile stress, the bottom layer buffers local deformation, and the overall strength is improved; through spatial heterogeneity, the surface layer is dense and the bottom layer is porous to achieve functional zoning, taking into account wear resistance, light weight and impact resistance;

[0030] Third, by mixing short fibers and long fibers of different lengths, synergistic reinforcement is achieved. Short fibers can fill the gaps between aluminum powder pores and long fibers, increase the density of the material, reduce interface defects, improve local strength, enhance interface bonding, reduce stress concentration, and improve material homogeneity. Long fibers can span multiple pores to form a continuous three-dimensional reinforcement network, bear the main load, and significantly improve the overall tensile strength and elongation at break of the material. During the fiber mixing and arrangement process, horizontal and vertical vibrations are applied to guide the fibers to arrange in multiple directions. Horizontal vibration promotes the longitudinal arrangement of fibers and enhances the tensile properties of the material in the direction of force. Vertical vibration prevents fiber delamination and optimizes the distribution of fibers in three-dimensional space. It avoids anisotropy caused by a single orientation and improves the uniformity and integrity of the material.

[0031] Fourthly, by combining aluminum powder of different particle sizes with carbon fibers of different sizes, based on the size effect of materials and the principle of synergistic reinforcement of composite materials, that is, materials of different sizes can complement each other when compounded to form a better performance combination, nano aluminum powder provides high hardness and wear resistance, micron aluminum powder provides large pore structure and lightweight characteristics, short-cut carbon fibers enhance local strength and impact resistance, and long-cut carbon fibers form a continuous reinforcement network to improve overall tensile strength and wear resistance; the interface bonding force between aluminum powder and carbon fibers is enhanced by chemical bonding and physical interlocking, and the phenolic resin forms Al-OC bonds with the surface of alumina after carbonization to achieve chemical bonding; long fibers are embedded in nanopores through high-pressure vibration, and short fibers anchor micropores to form a physical interlocking structure, which enhances impact resistance through bridging and forms a three-dimensional reinforcement network; the synergistic effect of the interface strengthens and improves the overall performance of the composite material, making the interaction between the components closer, thereby improving the mechanical properties of the material. DETAILED DESCRIPTION

[0032] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by technicians in the technical field to which the present invention belongs; the terms used in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention; the term "and / or" used herein includes any and all combinations of one or more related listed items.

[0033] Embodiment 1: A lightweight wear-resistant sole material comprises the following raw materials in parts by weight: 55 parts of EPDM rubber, 10 parts of ultra-high molecular weight polyethylene, 25 parts of wear-resistant filler, 10 parts of reinforcing agent, 0.5 parts of stearic acid, 1 part of zinc stearate, 0.5 parts of antioxidant, and 1 part of vulcanizing agent;

[0034] The preparation of the wear-resistant filler comprises the following steps:

[0035] S1. Add aluminum powder to a 2-3.5% potassium dichromate aqueous solution, stir to obtain a slurry, then add sodium dodecyl sulfate, stir to form a foam slurry, and set aside;

[0036] The aluminum powder includes nano aluminum powder and micron aluminum powder, the particle size of the nano aluminum powder is 50-100nm, and the particle size of the micron aluminum powder is 5-10μm; the weight ratio of the nano aluminum powder to the micron aluminum powder is 3:7; the foam slurry includes nano foam slurry and micro foam slurry;

[0037] The preparation of nano foam slurry and micro foam slurry is specifically as follows:

[0038] S1.1 Add nano aluminum powder to a 2% potassium dichromate aqueous solution, stir magnetically for 6 hours, then add sodium dodecyl sulfate, stir at a high speed of 800 r / min for 8 hours to form a stable nano foam slurry;

[0039] Wherein, the weight ratio of nano aluminum powder, potassium dichromate aqueous solution and sodium dodecyl sulfate is 1.5:10:0.05;

[0040] S1.2 Add micron aluminum powder to a 3.5% potassium dichromate aqueous solution, stir magnetically for 8 hours, then add sodium dodecyl sulfate, stir at 600 r / min for 10 hours to form a micron foam slurry;

[0041] Wherein, the weight ratio of micron aluminum powder, potassium dichromate aqueous solution and sodium dodecyl sulfate is 3:10:0.07;

[0042] S2, adding carbon fiber and phenolic resin into water, stirring at a speed of 1000r / min for 60min to obtain slurry, then injecting the slurry into a mold, applying pressure to the mold to squeeze out water, maintaining the pressure for 30min to form a green body, then drying the green body at 75°C for 24h, then keeping it at 150°C for 1h and 180°C for 5h, grinding it into powder to obtain a carbon composite material;

[0043] The carbon fiber is short viscose-based carbon fiber, and the weight ratio of short chopped viscose-based carbon fiber, phenolic resin and water is 60:12:100;

[0044] S3, mixing the nano foam slurry and the micro foam slurry to form a homogeneous mixed foam slurry;

[0045] The carbon composite material is added to the foam slurry, and then negative pressure impregnation is used to fill the carbon composite material into the pores of the foam slurry to form a mixed slurry, and the mixed slurry is dried at 75°C until the solvent is removed, and then cracked in a tubular furnace at a temperature of 1200°C for 2 hours under nitrogen protection, and cooled to obtain a wear-resistant filler;

[0046] Wherein, the weight ratio of the carbon composite material to the foam slurry is 4:30;

[0047] The method for preparing the lightweight wear-resistant sole material comprises the following steps:

[0048] A1. Mix EPDM rubber, ultra-high molecular weight polyethylene, wear-resistant filler and reinforcing agent evenly, pour into internal mixer, and mix at 100℃ for 10 minutes;

[0049] A2. Add stearic acid, zinc stearate and antioxidant, raise the temperature to 120°C, continue mixing for 10 minutes to obtain a mixed rubber, add a vulcanizing agent and vulcanize at 150°C for 5 minutes. After the vulcanization, melt granulate and compression mold at a pressure of 15 MPa for 5 minutes to obtain a wear-resistant sole material.

[0050] The performance of the wear-resistant sole material prepared by the technical solution of this embodiment is tested;

[0051] Performance testing:

[0052] Wear resistance: verified by Taber abrasion tester (ASTM D4060), 1000 revolutions, load 10N;

[0053] Tensile strength and elongation at break (%): Based on ASTM D412 tensile test, specimen Type C, speed 500 mm / min;

[0054] Density: Determined by buoyancy method (ASTM D792);

[0055] The comparative example is prepared by the patent method with application number CN202210376432.7. The difference from this embodiment is that double-particle size aluminum powder is not introduced for gradient distribution. The results are shown in the following table:

[0056] Wear resistance(mm) Tensile strength(MPa) <![CDATA[Density (g / cm 3 )]]> Elongation at break (%) Comparative Example 2.8 12.2 1.25 630 Embodiment 1 2.5 12.8 1.20 632

[0057] The technical solutions in the above embodiments of the present application have at least the following technical effects or advantages:

[0058] As can be seen from the table above, compared with the comparative example, the wear resistance of the technical solution of this embodiment is improved, the wear amount is reduced from 2.8mm to 2.5mm, a decrease of 11%, and the density is reduced from 1.25g / cm 3 Down to 1.20g / cm 3 , decreased by 4%, tensile strength increased by 5%, and elongation at break increased slightly;

[0059] By introducing aluminum powders of nanometer and micrometer particle sizes, a synergistic effect is produced. Nano aluminum powder has a high specific surface area and activity, can fill micrometer-level pores, reduce interface defects, and densify the surface, thereby reducing wear. In the preparation of wear-resistant fillers, nano aluminum powder can be more evenly dispersed in the matrix material to form more interface bonding points, thereby improving the overall strength and wear resistance of the material; the macroporous structure formed by micron aluminum powder can effectively absorb impact energy, buffer impact, avoid stress concentration, and improve the impact resistance of the material; particles of different particle sizes will form a gradient distribution in the mixed system, that is, the gaps between large particles are filled by small particles. This structure can more effectively utilize space and improve the density and uniformity of the material. In the preparation of wear-resistant fillers, the gradient distribution of nano aluminum powder and micron aluminum powder can increase the specific surface area of ​​the filler and improve the bonding force with the matrix material, thereby improving the wear resistance and mechanical properties of the material; micron aluminum powder can provide better load-bearing capacity and impact resistance, while nano aluminum powder can provide better interface bonding and wear resistance. By combining the two, the material performance can be further improved;

[0060] During the slurry preparation process, nano- and micron-sized aluminum powders are graded and regulated by shear forces at different speeds. High-speed shear forces make nano-aluminum powders evenly dispersed; low-speed stirring retains the pore structure of micron-sized aluminum powders and maintains the lightweight of the material; the densification effect of nano-aluminum powders significantly improves the wear resistance of the material, and the macroporous structure formed by micron-sized aluminum powders effectively absorbs impact energy and improves the impact resistance of the material; the graded regulation of shear forces reduces the amount of alumina used, while retaining the pore structure of the material, thereby reducing the density of the material;

[0061] The improved wear resistance makes the sole more durable, able to resist the wear and tear during daily walking and extend the service life of the shoes; the lightweight design makes the shoes lighter, reducing the burden when walking, and the enhanced impact resistance enables the sole to better absorb and disperse impact energy.

[0062] Example 2: The above-mentioned Example 1 introduces aluminum powder of different particle sizes and uses shear force to regulate, thereby improving the wear resistance, impact resistance and lightweight of the sole material, thereby achieving an improvement in the comprehensive performance of the sole material. In order to further improve the comprehensive performance of the material, further improvements are made on the basis of Example 1.

[0063] In step S3, the micron foam slurry and the nano foam slurry are injected in layers to form a gradient foam slurry. Specifically, the micron foam slurry is injected into the bottom layer of the mold and stirred at a low speed of 500 r / min for 5 minutes to form a loose porous structure; the nano foam slurry is injected into the surface layer, and a high-speed shear force of 800 r / min is simultaneously applied for 10 minutes to form a dense wear-resistant layer; a medium speed of 600 r / min is applied at the interface for 5 minutes to form a gradient foam slurry to ensure that the two layers are tightly combined.

[0064] The performance of the sole material prepared by the technical solution of this embodiment is tested. The difference between the technical solution of this embodiment and the technical solution of the first embodiment is that the first embodiment does not use layered injection to form a gradient foam slurry;

[0065] After testing, the wear resistance (mm) of the sole material prepared in this embodiment is 2.2, the tensile strength (MPa) is 13.5, the elongation at break (%) is 640, and the density (g / cm 3 ) is 1.15.

[0066] The technical solutions in the above embodiments of the present application have at least the following technical effects or advantages:

[0067] The test results show that the wear resistance is further improved, which is 12% of that in Example 1, and the density is reduced to 1.15 g / cm 3 , which is further reduced by 4.2% compared with Example 1, and the tensile strength is further increased to 13.5MPa, an increase of 5.5%;

[0068] By adopting a layered method of injecting micron foam slurry into the bottom layer and nano foam slurry into the surface layer, a gradient structure is formed, so that when the material is subjected to external force, each layer can work together to disperse and absorb energy layer by layer. The bottom layer adopts loose and porous micro foam slurry, which is conducive to absorbing and dispersing impact energy, reducing local stress concentration, and improving impact resistance and comfort; the surface layer adopts dense and wear-resistant nano foam slurry, which can resist wear and scratches. The gradient structure optimizes the load transfer path, the surface layer bears tensile stress, the bottom layer buffers local deformation, and the overall strength is improved; through spatial heterogeneity, the surface layer is dense and the bottom layer is porous to achieve functional zoning, taking into account wear resistance, light weight and impact resistance;

[0069] During the injection process, low-speed stirring is applied to the bottom layer of micron foam slurry to retain the macroporous structure of micron aluminum powder, form a loose porous structure, and form a lightweight, highly elastic buffer layer. High-speed shear force is applied to the surface nano foam slurry to promote the uniform dispersion of nano aluminum powder and form a dense wear-resistant layer. Medium-speed stirring is applied at the interface to eliminate interlayer pores and interface defects, promote the interlocking combination of nano and micro particles, form chemical bonds Al-OC and physical interlocking, and embed nano particles into micro pores to ensure that the two layers are tightly combined to form a transition layer and enhance the bonding force between the layers. Different speeds of shear force regulate the microstructure and performance of the foam slurry to avoid uneven dispersion caused by direct mixing of nano and micro particles, such as nano particle agglomeration or micro pore blockage. The pore distribution is controlled by layering so that the material has different mechanical properties in different parts.

[0070] The surface nano-foam slurry is treated with high-speed shear force to form a dense wear-resistant layer. The dense structure can effectively resist external wear and protect the underlying material from damage, thereby significantly improving the wear resistance of the material; the gradient structure enables the material to absorb and disperse energy layer by layer when impacted. The loose and porous micron foam layer at the bottom can absorb most of the impact energy, while the dense nano-foam layer on the surface can resist the remaining impact, thereby enhancing the impact resistance of the material; through gradient stratification and shear force regulation, the material has different properties and structures. This design enables the material to maintain high strength while still having good toughness; the gradient structure and shear force regulation enable the material to use space more effectively and improve the density and uniformity of the material.

[0071] Embodiment 3: The above-mentioned embodiment 2 improves the wear resistance, impact resistance and lightweight degree of the sole material through the gradient structural distribution of aluminum powder with different particle sizes, thereby achieving an improvement in the comprehensive performance of the sole material. In order to further improve the comprehensive performance of the material, further improvements are made on the basis of embodiment 2.

[0072] In step S2, the carbon fiber further comprises long-cut viscose-based carbon fiber, the short-cut viscose-based carbon fiber is 1-3 mm, the long-cut viscose-based carbon fiber is 5-8 mm, and the weight ratio of the short-cut viscose-based carbon fiber to the long-cut viscose-based carbon fiber is 7:3;

[0073] The preparation of carbon composite materials containing carbon fibers of different sizes is specifically as follows:

[0074] The short-cut viscose-based carbon fiber and the long-cut viscose-based carbon fiber were mixed in proportion, phenolic resin and water were added, and the mixture was stirred at 1200 r / min for 60 minutes to ensure that the fibers were evenly dispersed to prepare a slurry. The slurry was then injected into a mold, a vertical pressure of 8 MPa was applied to the mold, and horizontal vibration of 50 Hz and vertical vibration of 30 Hz were simultaneously turned on for 10 minutes;

[0075] The green body was formed by holding the pressure for 30 minutes, and then dried at 75°C for 24 hours, and then kept at 150°C for 1 hour and 180°C for 5 hours;

[0076] A low shear ball mill was used with a rotation speed of 200 r / min and a grinding time of 20 minutes to control the fiber breakage rate to <15%. The powder was obtained by sieving and long fiber fragments >3 mm were retained, accounting for ≥25%, to form a carbon composite material.

[0077] The performance of the sole material prepared by the technical solution of this embodiment is tested. The difference between the technical solution of this embodiment and the technical solution of the second embodiment is that the second embodiment does not use carbon fibers of different sizes;

[0078] After testing, the wear resistance (mm) of the sole material prepared in this embodiment is 2.0, the tensile strength (MPa) is 14.8, the elongation at break (%) is 660, and the density (g / cm 3 ) is 1.12.

[0079] The technical solutions in the above embodiments of the present application have at least the following technical effects or advantages:

[0080] By mixing short fibers and long fibers of different lengths, synergistic reinforcement is achieved. Short fibers can fill the gaps between aluminum powder pores and long fibers, increase the density of the material, reduce interface defects, improve local strength, enhance interface bonding, reduce stress concentration, and improve material homogeneity. Long fibers can span multiple pores to form a continuous three-dimensional reinforcement network, bear the main load, and significantly improve the overall tensile strength and elongation at break of the material. During the fiber mixing and arrangement process, horizontal and vertical vibrations are applied to guide the fibers to arrange in multiple directions. Horizontal vibration promotes the longitudinal arrangement of fibers and enhances the tensile properties of the material in the direction of force. Vertical vibration prevents fiber delamination and optimizes the distribution of fibers in three-dimensional space to avoid anisotropy caused by a single orientation, thereby improving the uniformity and integrity of the material.

[0081] The continuous network structure of long fibers bears the main load, and the auxiliary role of short fibers further enhances the tensile properties of the material; vibration regulates the fiber orientation so that the fibers are evenly distributed in three-dimensional space, thereby improving the overall tensile strength of the material; the three-dimensional distribution of the fibers delays the expansion of cracks and improves the elongation at break of the material; the filling effect of short fibers reduces interface defects, making the material more uniform when subjected to stress and reducing stress concentration; short fibers fill the pores of aluminum powder, reducing surface wear and improving the wear resistance of the material; the gradient distribution structure of aluminum powder also makes the surface layer denser, further enhancing the wear resistance, and the wear resistance is further reduced by 9% compared with Example 1; by optimizing the ratio of fiber and aluminum powder and process parameters, the lightweight characteristics of the material are maintained, and the improved material has higher tensile strength, toughness and wear resistance, and is suitable for sports shoes that need to withstand large loads and wear, such as basketball shoes, military shoes or industrial protective soles.

[0082] Embodiment 4: The above-mentioned embodiment 3 improves the wear resistance, impact resistance and lightweight of the sole material by introducing carbon fibers of different sizes and regulating the fiber orientation through bidirectional vibration, thereby achieving an improvement in the comprehensive performance of the sole material. In order to further improve the comprehensive performance of the material, further improvements are made on the basis of embodiment 3.

[0083] The short-cut viscose-based carbon fibers and the long-cut viscose-based carbon fibers are pretreated respectively to obtain a short-carbon composite material and a long-carbon composite material;

[0084] The pretreatment is specifically as follows: after the short-cut viscose-based carbon fiber is mixed with the phenolic resin, it is stirred at 1000r / min for 60min, injected into a mold and subjected to a pressure of 5MPa, the synchronous horizontal vibration frequency is 40Hz, 10min, and the pressure is maintained for 30min to form a green body, and then the green body is dried at 75°C for 24h, and then successively kept at 150°C for 1h and 180°C for 5h, and ground into powder to obtain a short carbon composite material;

[0085] The weight ratio of chopped carbon fiber, phenolic resin and water is 7:10:100;

[0086] After the long-cut viscose-based carbon fiber is mixed with the phenolic resin, it is stirred at 1200r / min for 60min, injected into the mold and subjected to a pressure of 10MPa, and the synchronous vertical vibration frequency is 50Hz for 10min to obtain a long carbon composite material; the pressure is maintained for 30min to form a green body, and then the green body is dried at 75℃ for 24h, and then kept at 150℃ for 1h and 180℃ for 5h, and the long fiber fragments are ground to retain>3mm, accounting for ≥25%, to form a long carbon composite material;

[0087] In step S3, the short carbon composite material is injected into the micron foam slurry, and the large pores are filled by negative pressure impregnation, and the long carbon composite material is injected into the nano foam slurry, and the small pores are filled by negative pressure impregnation; a medium speed stirring of 600r / min is applied at the interface for 5 minutes to eliminate interlayer defects.

[0088] The performance of the sole material prepared by the technical solution of this embodiment is tested. The difference between the technical solution of this embodiment and the technical solution of the third embodiment is that the third embodiment does not use aluminum powders of different particle sizes and carbon fibers of different sizes to combine;

[0089] After testing, the wear resistance (mm) of the sole material prepared in this embodiment is 1.6, the tensile strength (MPa) is 15.9, the elongation at break (%) is 680, and the density (g / cm 3 ) is 1.08.

[0090] The technical solutions in the above embodiments of the present application have at least the following technical effects or advantages:

[0091] By combining aluminum powder of different particle sizes with carbon fibers of different sizes, based on the size effect of materials and the principle of synergistic enhancement of composite materials, that is, materials of different sizes can complement each other when compounded to form a better performance combination, nano aluminum powder provides high hardness and wear resistance, micron aluminum powder provides large pore structure and lightweight characteristics, short-cut carbon fibers enhance local strength and impact resistance, and long-cut carbon fibers form a continuous reinforcement network to improve overall tensile strength and wear resistance; the interface bonding force between aluminum powder and carbon fibers is enhanced by chemical bonding and physical interlocking, and phenolic resin forms Al-OC bonds with the surface of alumina after carbonization to achieve chemical bonding; long fibers are embedded in nanopores through high-pressure vibration, and short fibers anchor micropores to form a physical interlocking structure, which enhances impact resistance through bridging and forms a three-dimensional reinforcement network; the synergistic effect of the interface strengthens and improves the overall performance of the composite material, making the interaction between the components closer, thereby improving the mechanical properties of the material;

[0092] Through step-by-step pressure control and optimization of vibration parameters, the micron layer uses low pressure to protect the pore structure, the nano layer uses high pressure to promote fiber penetration, horizontal vibration optimizes short fiber dispersion, and vertical vibration orients long fibers. By precisely controlling the processing conditions, the material's microstructure and performance are further optimized during processing.

[0093] Long fibers strengthen nanopores to form a dense wear-resistant layer, which effectively resists external wear; short fibers fill micron pores, reduce pore defects, and improve the overall wear resistance of the material. The improvement of wear resistance enables the sole material to maintain good surface integrity and performance stability during long-term use; long fibers carry loads across layers to form a continuous reinforcement network, which improves the overall tensile strength of the material; short fibers enhance local strength, so that the material can evenly distribute stress when subjected to force to avoid local damage, and the enhancement of tensile strength enables the sole material to maintain good structural integrity and safety when subjected to large tensile forces; multi-level fibers synergistically inhibit crack propagation, so that the material can absorb more energy when it breaks; the improvement of interface toughness enables the material to undergo large plastic deformation when subjected to force and is not easy to break, and the improvement of elongation at break enables the sole material to have better cushioning performance and adaptability when subjected to impact or stretching; pore grading optimization enables the material to reduce the invalid space and density while maintaining good performance; fiber filling further reduces the weight of the material, and the reduction in density enables the sole material to reduce the overall weight of the shoe while maintaining good performance, thereby improving the comfort and convenience of wearing.

[0094] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A lightweight and wear-resistant sole material, characterized in that: The invention comprises the following raw materials in parts by weight: 55 parts of EPDM rubber, 10 parts of ultra-high molecular weight polyethylene, 25 parts of wear-resistant filler, 10 parts of reinforcing agent, 0.5 parts of stearic acid, 1 part of zinc stearate, 0.5 parts of antioxidant, and 1 part of vulcanizing agent; The preparation of the wear-resistant filler comprises the following steps: S1. Add aluminum powder to a 2-3.5% potassium dichromate aqueous solution, stir to obtain a slurry, then add sodium dodecyl sulfate, stir to form a foam slurry, and set aside; The aluminum powder includes nano aluminum powder and micron aluminum powder, the particle size of the nano aluminum powder is 50-100nm, the particle size of the micron aluminum powder is 5-10μm, and the weight ratio of the nano aluminum powder to the micron aluminum powder is 3:7; the foam slurry includes nano foam slurry and micro foam slurry; S2, adding carbon fiber and phenolic resin into water, stirring at a speed of 1000r / min for 60min to obtain slurry, then injecting the slurry into a mold, applying pressure to the mold to squeeze out water, maintaining the pressure for 30min to form a green body, then drying the green body at 75°C for 24h, then keeping it at 150°C for 1h and 180°C for 5h, grinding it into powder to obtain a carbon composite material; S3, mixing the nano foam slurry and the micro foam slurry to form a homogeneous mixed foam slurry; The carbon composite material is added to the foam slurry, and then negative pressure impregnation is used to fill the carbon composite material into the pores of the foam slurry to form a mixed slurry. The mixed slurry is dried at 75°C until the solvent is removed, and then cracked in a tubular furnace at 1200°C for 2 hours under nitrogen protection, and cooled to obtain a wear-resistant filler.

2. The lightweight wear-resistant sole material according to claim 1, characterized in that: The preparation of nano foam slurry and micro foam slurry is specifically as follows: S1.1 Add nano aluminum powder to a 2% potassium dichromate aqueous solution, stir magnetically for 6 hours, then add sodium dodecyl sulfate, stir at a high speed of 800 r / min for 8 hours to form a stable nano foam slurry; S1.2 Add micron aluminum powder to a 3.5% potassium dichromate aqueous solution, stir magnetically for 8 hours, then add sodium dodecyl sulfate, stir at 600 r / min for 10 hours to form a micron foam slurry.

3. The lightweight wear-resistant sole material according to claim 2, characterized in that: In step S1.1, the weight ratio of nano-aluminum powder, potassium dichromate aqueous solution and sodium dodecyl sulfate is 1.5:10:0.05; In step S1.2, the weight ratio of micron aluminum powder, potassium dichromate aqueous solution and sodium dodecyl sulfate is 3:10:0.

07.

4. The lightweight wear-resistant sole material according to claim 1, characterized in that: In step S3, the micron foam slurry and the nano foam slurry are injected in layers to form a gradient foam slurry.

5. The lightweight wear-resistant sole material according to claim 4, characterized in that: The layered injection is specifically, injecting the micron foam slurry into the bottom layer of the mold, stirring at a low speed of 500r / min for 5min; injecting the nano foam slurry into the surface layer, and simultaneously applying a high-speed shear force of 800r / min for 10min; A medium speed of 600 r / min was applied at the interface for 5 min to form a gradient foam slurry.

6. The lightweight wear-resistant sole material according to claim 4, characterized in that: In step S2, the carbon fiber also includes long-cut viscose-based carbon fiber, wherein the short-cut viscose-based carbon fiber is 1-3 mm, and the long-cut viscose-based carbon fiber is 5-8 mm.

7. The lightweight wear-resistant sole material according to claim 6, characterized in that: The weight ratio of the short-cut viscose-based carbon fibers to the long-cut viscose-based carbon fibers is 7:

3.

8. The lightweight wear-resistant sole material according to claim 6, characterized in that: The short-cut viscose-based carbon fibers and the long-cut viscose-based carbon fibers are pretreated respectively to obtain a short-carbon composite material and a long-carbon composite material.

9. The lightweight wear-resistant sole material according to claim 8, characterized in that: In step S3, the short carbon composite material is injected with micron foam slurry, and the long carbon composite material is injected with nano foam slurry.

10. A method for preparing the lightweight wear-resistant sole material according to any one of claims 1 to 9, characterized in that: The steps include: A1. Mix EPDM rubber, ultra-high molecular weight polyethylene, wear-resistant filler and reinforcing agent evenly, pour into internal mixer, and mix at 100℃ for 10 minutes; A2. Add stearic acid, zinc stearate and antioxidant, raise the temperature to 120°C, continue mixing for 10 minutes to obtain a mixed rubber, add a vulcanizing agent and vulcanize at 150°C for 5 minutes. After the vulcanization, melt granulate and compression mold at a pressure of 15 MPa for 5 minutes to obtain a wear-resistant sole material.