Algae Biomass Filler in Elastomer Composites
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Solution Overview
Problem
Current elastomer composites lack sustainable filler materials that effectively enhance mechanical and thermal properties while reducing environmental impact, particularly in industries like footwear and automotive parts.
Innovation Solution
A biomass-elastomer composite is developed using algae biomass as a reinforcement filler, combined with additives and processing methods that include drying and milling to achieve desired properties, such as improved abrasion resistance and durability, and can be used in various forms like solid or foam composites.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fossil fuel-based fillers are used in elastomer composites, then mechanical and thermal properties can be achieved, but environmental impact increases and sustainability is compromised
Solution Approach 1:
The patent transforms the chemical composition parameters of filler materials from petroleum-based hydrocarbons to algae-derived biomass containing cellulose, hemicellulose, and lignin. This parameter change maintains structural reinforcement capabilities while eliminating fossil fuel dependency and reducing environmental harm.
Solution Approach 2:
The patent creates a composite filler system combining multiple algae-derived components (cellulose fibers, hemicellulose, lignin) to replicate the multi-functional performance of traditional fillers. The synergistic combination provides both mechanical reinforcement and thermal stability while maintaining sustainability.
2Object-affected harmful factors
If algae biomass is used as filler in elastomer composites, then sustainability and ecological benefits are improved, but mixing and processing challenges arise due to biomass characteristics
Solution Approach 1:
The patent introduces surface treatment agents and compatibilizers as intermediary substances that facilitate bonding between hydrophilic algae biomass particles and hydrophobic elastomer matrices. These intermediaries resolve the immiscibility issue and enable effective stress transfer.
Solution Approach 2:
The patent modifies physical parameters of algae biomass including particle size reduction through milling and surface chemistry modification through treatment processes. These parameter changes improve dispersibility and reduce agglomeration during mixing operations.
3Reliability
If algae biomass filler is incorporated into elastomer matrix, then renewable and sustainable composite material is achieved, but dispersion uniformity and mixing homogeneity become difficult to achieve
Solution Approach 1:
The patent divides algae biomass into smaller individual particles through mechanical milling and size reduction processes. This segmentation prevents agglomeration and enables more uniform distribution throughout the elastomer matrix during compounding.
Solution Approach 2:
The patent employs dispersing agents and surface treatments as intermediaries that reduce particle-particle interactions and enhance particle-matrix adhesion. These intermediaries promote uniform dispersion by preventing biomass particle aggregation.
Data Source
AI summary
An algae-elastomer composite including an elastomer matrix; algae; and a mixing additive sufficient to achieve a desired property. The algae can be present in a milled condition having a particle size value of between about 10 and 120 microns. The algae is mixed with the elastomer matrix in a dry condition having a moisture content of below about 10%. A method of preparing the algae-based elastomer composite is provided that includes the steps of: premixing an elastomer matrix; adding an algae filler; adding a mixing additive that includes a plasticizer; forming an elastomer-algae blend by blending the algae and elastomer to a temperature sufficient to be further mixed, wherein the temperature is about 10° C. higher than the temperature sufficient for the elastomer alone; adding and mixing a curing or vulcanizing agent for the elastomer dispersing the elastomer-algae blend; and heating and curing the elastomer-algae blend into a final form.