Devulcanized Rubber Composite for Shoe Outsole Manufacturing
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Solution Overview
Problem
The shoe industry faces challenges in recycling rubber waste due to differing material standards from the tire industry, and current methods limit the efficient reuse of vulcanized rubber powder in shoe outsole production, resulting in inefficient waste management and environmental pollution.
Innovation Solution
A method involving devulcanization of scrap rubber to produce reclaimed rubber, which is then compounded with a basic rubber formulation and a crosslinking agent to create a reclaimed material that meets the mechanical properties required for shoe outsoles, allowing for increased reuse of recycled rubber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If vulcanized rubber powder is added as filler into original rubber formulation, then reuse efficiency is improved, but crosslinking difficulty reduces mechanical properties
Solution Approach 1:
The patent applies parameter changes by modifying the chemical state of rubber powder from vulcanized to devulcanized. This transforms the crosslinked network structure into a more reactive state that can重新参与硫化反应，allowing higher incorporation levels (5-30 wt%) while maintaining mechanical properties and enabling effective rubber waste reuse.
Solution Approach 2:
The patent creates a composite material system combining devulcanized rubber powder with uncured rubber compounds and crosslinking agents. This composite approach allows the devulcanized rubber to function as an active reinforcing phase that can重新交联，achieving both high waste content and satisfactory mechanical performance.
2Ease of manufacture
If rubber waste is ground into powder and reused, then recycling process is simplified, but limited incorporation ratio reduces waste consumption
Solution Approach 1:
The patent changes the chemical parameter of rubber powder from vulcanized to devulcanized state. This simple parameter change enables the powder to重新参与硫化反应，increasing the feasible incorporation ratio from 3-5 wt% to 5-30 wt% and significantly improving waste consumption efficiency while maintaining process simplicity.
Solution Approach 2:
The patent introduces crosslinking agents as intermediaries that facilitate the重新交联 process between devulcanized rubber powder and the rubber matrix. This intermediary enables effective bonding and network formation, allowing higher rubber powder content while maintaining mechanical integrity and waste reuse efficiency.
3Adaptability or versatility
If tire rubber waste recycling process is applied to shoe industry, then recycling capability is provided, but material standard mismatch prevents effective application
Solution Approach 1:
The patent changes the chemical state of rubber from vulcanized to devulcanized, fundamentally altering its processing characteristics. This parameter change enables shoe industry rubber waste to be recycled with methods closer to tire industry approaches while meeting shoe-specific material standards, achieving both adaptability and manufacturing precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively recycles rubber waste by producing a reclaimed material with improved mechanical properties, enhancing the efficiency of rubber reuse and contributing to a circular economy by reducing waste in the shoe manufacturing process.
Implementation Method 1
make the scrap rubber granules undergo a devulcanization reaction to form a reclaimed rubber
Implementation Method 2
A manufacturing process of the shoe outsole material needs to undergo a process of vulcanization to improve the performance of the outsole material
Data Source
AI summary
A method of producing a reclaimed rubber made of recycled shoe material waste includes the following steps. Step S1: collect a scrap rubber which is the shoe material waste. Step S2: grind the scrap rubber to form scrap rubber granules. Step S3: devulcanize the scrap rubber granules to form a reclaimed rubber. A reclaimed material for manufacturing shoes includes a reclaimed rubber formulation and a crosslinking agent, wherein the reclaimed rubber formulation is constituted by compounding a basic rubber formulation and the reclaimed rubber, wherein the reclaimed material for manufacturing shoes includes 65-94.8 wt % of the basic rubber formulation, 5-30 wt % of the reclaimed rubber, and 0.2 wt % to 5 wt % of crosslinking agent. Mechanical properties of the reclaimed material for manufacturing shoes meet required standards of shoe outsole material. A method of consuming rubber waste produced during the shoe manufacturing process is disclosed herein.