Foamed rubber shoe material and method for preparing the same
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Solution Overview
Problem
Existing foamed rubber shoe materials face issues with bubble collapse during the vulcanization process due to the use of low-boiling-point chemical foaming agents and physical foaming agents, leading to inadequate foaming and densification of rubber materials.
Innovation Solution
A foamed rubber shoe material is developed using a combination of triterpenoid saponin, n-butanol, unsaturated fatty acid, and dicumyl peroxide, which enhances the strength of the bubble wall through copolymerization and hydrogen bonding, preventing bubble collapse and promoting sufficient foaming. The rubber matrix includes natural rubber and prevulcanized rubber, along with modified fiberglass for improved compatibility and crosslinking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a combination of chemical foaming agents and physical foaming agents with different decomposing temperatures is used, then the foaming adequacy is improved, but the bubbles are easy to break through the bubble wall causing collapse and densification
Solution Approach 1:
The patent introduces a protective colloid as an intermediary substance that mediates between the foaming agents and the rubber matrix. This protective colloid forms a stable interface around bubbles, preventing them from breaking through the bubble wall while maintaining adequate foaming. The intermediary substance resolves the contradiction by providing both foaming capability and bubble wall stability simultaneously.
Solution Approach 2:
The patent uses a composite foaming system combining multiple foaming agents (chemical and physical) with different decomposing temperatures, each contributing to different stages of foaming. This composite approach ensures comprehensive foaming adequacy while the protective colloid maintains bubble wall integrity, resolving the contradiction between foaming effectiveness and bubble stability.
2Quantity of substance
If multiple foaming agents with different decomposing temperatures are combined, then sufficient foaming is achieved, but the bubble wall collapses due to softening action of released bubbles
Solution Approach 1:
The protective colloid acts as a mediator that reinforces the bubble wall structure. It forms a protective layer around the bubbles generated by multiple foaming agents, preventing the softening action from compromising bubble wall strength. This allows sufficient foaming volume to be achieved while maintaining bubble wall integrity.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the bubble wall by introducing the protective colloid, which changes the interfacial properties and strengthens the bubble wall. This parameter change enables the bubble wall to withstand the softening action while maintaining sufficient foaming volume.
3Productivity
If chemical foaming agents with low boiling point and physical foaming agents are used, then foaming activity is enhanced, but bubble collapse occurs leading to densification
Solution Approach 1:
The protective colloid serves as an intermediary that stabilizes the foam structure during the foaming process. It allows high foaming activity from multiple agents while preventing bubble collapse, thus maintaining foam structure integrity and preventing densification.
Solution Approach 2:
The protective colloid provides beforehand cushioning to the bubble walls, preparing them to withstand the stresses of foaming activity. This prior protection prevents bubble collapse and maintains structural integrity throughout the foaming process.
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 solution significantly improves the breathability and sweat-wicking properties of the shoe material by maintaining bubble integrity, resulting in better foaming and reduced densification, enhancing the overall performance of the rubber material.
Implementation Method 1
During the vulcanization process of the rubber, the foaming agent undergoes physical and chemical changes to form gas
Implementation Method 2
the hydrophilic ends form hydrogen bonds at the inner side of the bubble wall
Implementation Method 3
the triterpenoid saponins can copolymerize with the unsaturated fatty acid and the natural rubber on the outer side of the bubble wall under the action of dicumyl peroxide
Implementation Method 4
the n-butanol itself can be foamed by vaporization, playing a role of foaming agent
Data Source
AI summary
A foamed rubber shoe material is obtained from a rubber shoe base material by vulcanization, foaming, and cutting, the rubber shoe base material includes a rubber sheet and a cloth attached on the rubber sheet, the rubber sheet is prepared from a premixed rubber material in an open mill, the premixed rubber material includes the following components in parts by weight: 44-48 parts of rubber matrix, 24-28 parts of a filler, 5-7 parts of an oil material, 4-5 parts of a vulcanization agent, 1.8-2.2 parts of an antiager, 0.5-0.7 parts of an accelerator, 4-6 parts of triterpenoid saponin, 8-12 parts of n-butanol, 3-5 parts of an unsaturated fatty acid, 7-9 parts of sulfur, 1.6-2.4 parts of dicumyl peroxide, and 10-14 parts of a foaming agent, the foaming agent includes a combination of 4,4′-oxybis(benzenesulfonyl hydrazide), petroleum ether, dichloroethane and at least one bicarbonate, and the rubber matrix includes a natural rubber.